US20230121434A1 - Tonneau Cover Having Secured Flexible Hinge - Google Patents
Tonneau Cover Having Secured Flexible Hinge Download PDFInfo
- Publication number
- US20230121434A1 US20230121434A1 US18/068,949 US202218068949A US2023121434A1 US 20230121434 A1 US20230121434 A1 US 20230121434A1 US 202218068949 A US202218068949 A US 202218068949A US 2023121434 A1 US2023121434 A1 US 2023121434A1
- Authority
- US
- United States
- Prior art keywords
- panel
- secured
- cab
- rigid
- cargo box
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 230000007246 mechanism Effects 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims description 114
- 238000003860 storage Methods 0.000 claims description 50
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 23
- 230000004888 barrier function Effects 0.000 claims description 4
- 230000005484 gravity Effects 0.000 claims 3
- 239000000853 adhesive Substances 0.000 description 127
- 230000001070 adhesive effect Effects 0.000 description 127
- 125000006850 spacer group Chemical group 0.000 description 92
- 230000036961 partial effect Effects 0.000 description 62
- 239000002390 adhesive tape Substances 0.000 description 53
- 239000012790 adhesive layer Substances 0.000 description 49
- 239000002861 polymer material Substances 0.000 description 44
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 32
- 230000001681 protective effect Effects 0.000 description 32
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 27
- 239000006261 foam material Substances 0.000 description 22
- 238000005452 bending Methods 0.000 description 21
- 238000000576 coating method Methods 0.000 description 17
- 239000002184 metal Substances 0.000 description 14
- 229910052751 metal Inorganic materials 0.000 description 14
- 229920000642 polymer Polymers 0.000 description 14
- 238000001556 precipitation Methods 0.000 description 14
- 229910052782 aluminium Inorganic materials 0.000 description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 239000006260 foam Substances 0.000 description 11
- 230000000712 assembly Effects 0.000 description 10
- 238000000429 assembly Methods 0.000 description 10
- 239000011248 coating agent Substances 0.000 description 10
- 230000007704 transition Effects 0.000 description 10
- 239000004677 Nylon Substances 0.000 description 9
- 238000005299 abrasion Methods 0.000 description 9
- 230000006378 damage Effects 0.000 description 9
- 229920001778 nylon Polymers 0.000 description 9
- 230000000284 resting effect Effects 0.000 description 9
- 230000008901 benefit Effects 0.000 description 8
- 229920001971 elastomer Polymers 0.000 description 8
- 239000000835 fiber Substances 0.000 description 8
- 239000005060 rubber Substances 0.000 description 8
- 239000002131 composite material Substances 0.000 description 7
- 230000007423 decrease Effects 0.000 description 7
- 239000010410 layer Substances 0.000 description 7
- 229920000728 polyester Polymers 0.000 description 7
- 230000004224 protection Effects 0.000 description 7
- 230000003213 activating effect Effects 0.000 description 6
- 239000004744 fabric Substances 0.000 description 6
- 238000007789 sealing Methods 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000002156 mixing Methods 0.000 description 5
- 229920001084 poly(chloroprene) Polymers 0.000 description 5
- 229920000915 polyvinyl chloride Polymers 0.000 description 5
- 239000004800 polyvinyl chloride Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 229920001169 thermoplastic Polymers 0.000 description 5
- 229920002725 thermoplastic elastomer Polymers 0.000 description 5
- 229910000838 Al alloy Inorganic materials 0.000 description 4
- 229920002943 EPDM rubber Polymers 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 230000007613 environmental effect Effects 0.000 description 4
- 239000011152 fibreglass Substances 0.000 description 4
- 239000012943 hotmelt Substances 0.000 description 4
- 150000002739 metals Chemical class 0.000 description 4
- 239000003973 paint Substances 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 229920006342 thermoplastic vulcanizate Polymers 0.000 description 4
- 239000003522 acrylic cement Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000000428 dust Substances 0.000 description 3
- 229920006334 epoxy coating Polymers 0.000 description 3
- 229920005570 flexible polymer Polymers 0.000 description 3
- 239000003292 glue Substances 0.000 description 3
- 239000011253 protective coating Substances 0.000 description 3
- 239000012783 reinforcing fiber Substances 0.000 description 3
- 230000000717 retained effect Effects 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- 239000004416 thermosoftening plastic Substances 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 2
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- 208000027418 Wounds and injury Diseases 0.000 description 2
- 230000003466 anti-cipated effect Effects 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000009977 dual effect Effects 0.000 description 2
- 238000005530 etching Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000011151 fibre-reinforced plastic Substances 0.000 description 2
- 208000014674 injury Diseases 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920003052 natural elastomer Polymers 0.000 description 2
- 229920001194 natural rubber Polymers 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 239000012812 sealant material Substances 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- 239000004945 silicone rubber Substances 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 229910001204 A36 steel Inorganic materials 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229910001369 Brass Inorganic materials 0.000 description 1
- 239000004821 Contact adhesive Substances 0.000 description 1
- 208000034656 Contusions Diseases 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920002449 FKM Polymers 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 230000006750 UV protection Effects 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 238000007743 anodising Methods 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 229920005549 butyl rubber Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000009519 contusion Effects 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 239000013536 elastomeric material Substances 0.000 description 1
- -1 galvanized coatings Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 229920002681 hypalon Polymers 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 230000004941 influx Effects 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 238000003698 laser cutting Methods 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 150000002825 nitriles Chemical class 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 239000013047 polymeric layer Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229920003031 santoprene Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000012358 sourcing Methods 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
- B60J7/185—Locking arrangements
- B60J7/19—Locking arrangements for rigid panels
- B60J7/198—Locking arrangements for rigid panels for locking tonneau covers such as covers for roof storage compartments or for pick-up truck beds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
- B60J7/02—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of sliding type, e.g. comprising guide shoes
- B60J7/04—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of sliding type, e.g. comprising guide shoes with rigid plate-like element or elements, e.g. open roofs with harmonica-type folding rigid panels
- B60J7/041—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of sliding type, e.g. comprising guide shoes with rigid plate-like element or elements, e.g. open roofs with harmonica-type folding rigid panels for utility vehicles, e.g. with slidable and foldable rigid panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
- B60J7/08—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position
- B60J7/12—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position foldable; Tensioning mechanisms therefor, e.g. struts
- B60J7/14—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position foldable; Tensioning mechanisms therefor, e.g. struts with a plurality of rigid plate-like elements or rigid non plate-like elements, e.g. with non-slidable, but pivotable or foldable movement
- B60J7/141—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position foldable; Tensioning mechanisms therefor, e.g. struts with a plurality of rigid plate-like elements or rigid non plate-like elements, e.g. with non-slidable, but pivotable or foldable movement for covering load areas, e.g. for pick-up trucks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
- B60J7/08—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position
- B60J7/16—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position non-foldable and rigid, e.g. a one-piece hard-top or a single rigid roof panel
- B60J7/1607—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position non-foldable and rigid, e.g. a one-piece hard-top or a single rigid roof panel for covering load areas, e.g. rigid panels for pick-up truck beds
- B60J7/1621—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position non-foldable and rigid, e.g. a one-piece hard-top or a single rigid roof panel for covering load areas, e.g. rigid panels for pick-up truck beds hinged on one side
Definitions
- a tonneau cover apparatus for covering an open bed or cargo box of a pickup truck.
- the tonneau cover apparatus preferably including a folding cover assembly having a plurality of rigid panels that are interconnected in series by a series of hinges in such a manner that the respective panels can pivot with respect to one another, so as to fold up while the cover assembly is secured to a support frame assembly, when the support frame assembly is secured to the cargo box of the pickup truck.
- a plurality of the rigid panels can be secured in an upright folded orientation when the cover assembly is detachably secured to the pickup truck.
- a tonneau cover apparatus preferably includes two rigid panels, a cab panel that can be secured to a support frame assembly that is secured to a cargo box of a pickup truck and a lift-up panel that is pivotally interconnected in series with the cab panel when the cab panel is secured to the support frame assembly.
- the lift-up panel is interconnected to the cab panel by a hinge, preferably a flexible hinge
- the cover assembly includes two hinge support mechanism, each having opposing first and second hinge brackets secured to a lower surface of the cab panel and the lift-up panel, respectively, in such a manner that the respective panels can pivot with respect to one another with the guidance of the opposing guide brackets.
- tonneau covers Numerous protective cover assemblies for preventing rain, debris and wind from damaging or disrupting the contents of a pickup truck bed or cargo box are currently available.
- Some tonneau covers are made of a fabric material, often a fabric coated with a polymeric material, which is fastened to a rigid frame so as to enclose and protect the pickup truck cargo box.
- Various covering materials are used for such tonneau covers; some are flexible and/or stretchable, and others are more rigid, and they are secured to the pickup truck in various manners to cover the cargo box.
- Tonneau covers are opened in various manners to allow entry into the cargo box, such as by rolling the cover up, folding the cover up, lifting a hard cover upward or pivoting the cover upward, or disconnecting and removing the cover from the cargo box altogether, in some cases after the cover assembly is folded up.
- Typical tonneau covers have support frames including a pair of elongated side rails that are secured to the sidewalls of the cargo box of the pickup truck.
- Known tonneau covers are often secured to the side rails using hook and loop strip fastener components secured to the side rail, typically within a horizontal channel (see, e.g., U.S. Pat. Nos. 4,036,521; 4,991,640; 6,752,449 and U.S. Patent Application Pub. No. 2004/0212212 A1).
- Some tonneau covers are secured to the side rails by latches (see. e.g., U.S. Pat. No. 7,104,586).
- tonneau covers include rigid panels which are folded up for cargo access (see e.g., U.S. Pat. No. 10,189,340). While there are many, many tonneau covers, too many to review them all in this space, the present inventions provide improvements that address limitations associated with the prior art.
- the present invention preferably includes a tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position.
- the tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly preferably including a plurality of rigid panels.
- the cover assembly includes a flexible hinge; wherein the plurality of rigid panels, including first and second rigid panels which are pivotally secured to one another by a hinge, preferably the flexible hinge.
- the cover assembly includes a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another.
- the tonneau cover apparatus preferably further includes a mechanism for securing the respective upper surfaces of the at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the pickup truck, preferably a cab positioned forward of the cargo box and a securing member attached to the cover assembly, wherein the securing member can engage the bracket so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation.
- the securing member and the bracket are magnetically attracted to one another and the bracket will preferably contain a magnet.
- the securing member is made of steel and is magnetically attracted to the magnet contained in the bracket and the bracket is adhesively secured to the cab.
- the securing member is preferably an elongated rigid member that has first and second ends and the elongated rigid member is bent in such a way that first and second upper surfaces of the respective first and second ends of the elongated rigid member are oriented at an angle to one another of from about 1 degree to about 16 degrees.
- a method of removably securing the tonneau cover apparatus to the pickup truck is also provided.
- the method preferably including the steps of providing a support frame assembly for attachment to the cargo box; a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another; and 3) a mechanism for securing the respective upper surfaces of at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the cab and
- a tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of a cargo box including a forward end, two opposing sidewalls and a tailgate; the tailgate being positioned rearward of the forward end and having an open position and a closed position.
- the tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box.
- the cover assembly preferably having a plurality of rigid panels including first and second rigid panels that are pivotally interconnected with one another by a hinge; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the first rigid panel can be secured to the support frame assembly when the support frame assembly is secured to the pickup truck; wherein the cover assembly further includes a pair of hinge support mechanisms that generally restrict the way in which the second rigid panel pivots with respect to the first rigid panel; wherein each of the hinge support mechanisms include opposing first and second hinge support brackets secured to the lower surfaces of the first and second rigid panels, respectively, proximate the hinge so that the opposing first and second hinge support brackets of each of the respective hinge support mechanisms are slideably engaged with one another when the first and second rigid panels pivot with respect to one another.
- each of the respective opposing hinge support brackets include a guide pin and an arcuate guide slot; and wherein, when the support frame assembly is attached to the cargo box, the cover assembly is attached to the support frame assembly, and the second rigid panel pivots with respect to the first rigid panel, the respective guide pins of each of the opposing hinge support brackets slide within the respective arcuate slots of the opposing hinge support brackets.
- FIG. 1 is a rear perspective view of a folding tonneau cover apparatus according to the present invention, including a folding cover assembly and a support frame assembly, and shown attached to a pickup truck which is shown in phantom;
- FIG. 2 A is a top plan view showing the folding tonneau cover assembly shown in FIG. 1 and also showing a protective film 574 on the top surface of the front panel 536 c , that is not shown in subsequent Figures, with the exception of FIGS. 9 A, 10 A, and 10 B where the protective film shown is again shown;
- FIG. 2 B is a bottom plan view of the folding tonneau cover apparatus of FIG. 1 ;
- FIG. 2 C is a side view of the folding tonneau cover apparatus of FIG. 1 as viewed from line 2 C- 2 C of FIG. 2 A which illustrates the driver's side of the pickup truck shown in FIG. 1 ; however, for clarity of illustration, the perimeter seal on the underside of the outer edge of the respective panels is not shown;
- FIG. 2 D is a detailed view of a portion of the folding tonneau cover apparatus encircled by the dashed line 2 D, 19 A of FIG. 2 C , illustrating the rear hinge, with a portion of the driver's-side side rail broken away to show the underlying structure;
- FIG. 2 E is a detailed view of a portion of the folding tonneau cover apparatus encircled by dashed line 2 E of FIG. 2 C , illustrating the middle hinge and the front hinge, with a portion of the driver's-side side rail broken away to show the underlying structure;
- FIG. 2 F is an enlarged detailed top plan view of a portion of the folding tonneau cover apparatus shown in the dashed rectangle 2 F of FIG. 2 A , with portions broken away to show the underlying structure and showing the support member in partial cross section and illustrating the engaging portion of the latch engaged with the containment bracket and the side rail, and showing an alternate position of the engaging portion of the latch in phantom when it is retracted from the containment bracket and with other structures shown in phantom to indicate the relative position of the respective elements;
- FIG. 2 G is an enlarged perspective view as seen generally from a line 2 G- 2 G of FIG. 2 B which is seen from below of a portion of a folding tonneau cover apparatus similar to the folding tonneau cover apparatus shown in FIG. 2 B , except that the side rail shown in FIG. 2 G is an alternate passenger side rail 520 d , which differs from the side rail 520 b shown in FIG. 2 B ;
- FIG. 2 H is an exploded perspective view of an alternative driver's-side split side rail, that is a mirror image of the passenger side split side rail shown in FIG. 2 G , both of which have a plurality of sections which are joined together by a driver's side containment bracket;
- FIG. 3 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 , illustrating additional details;
- FIG. 3 B is a partial section view as seen from the line 3 B- 3 B of FIG. 3 A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom;
- FIG. 4 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 , with the release cord pulled to pull the latch against the bias of the spring to release the latch from the engagement with the side rail;
- FIG. 4 B is a is a partial section view as seen from the line 4 B- 4 B of FIG. 4 A similar to the view of FIG. 3 B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail;
- FIG. 5 A is schematic illustration of a vertical cross section along a front-to-back plane as seen from the line 5 A- 5 A of FIG. 2 A of one of the hinges of the folding tonneau cover assembly of FIG. 1 showing the basic configuration with the hinge unfolded;
- FIG. 5 B is a schematic illustration similar to FIG. 5 A of a transverse vertical cross section along a front-to-back plane showing an alternate embodiment of one of the hinges of the folding tonneau cover assembly of FIG. 1 showing the hinge unfolded;
- FIG. 5 C is a schematic illustration showing the hinge of FIG. 5 B , but with the hinge folded at about 45 degrees from the unfolded orientation shown in FIG. 5 B ;
- FIG. 5 D is a schematic illustration showing the general steps and configurations of the folding tonneau cover assembly of FIG. 1 as it is folded up into a fully folded orientation;
- FIG. 5 E is a further schematic illustration showing an alternate configuration of the fully folded orientation of the tonneau cover assembly of FIG. 5 D ;
- FIG. 5 F is a further schematic illustration similar to that of FIG. 5 E , but showing yet another alternate configuration of the fully folded tonneau cover assembly;
- FIG. 6 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 wherein the latches on the rear panel have been released to allow the rear panel to be lifted up in a first step toward folding up the tonneau cover assembly;
- FIG. 6 B is a partial section view as seen from line 6 B- 6 B of FIG. 6 A showing the hook or swing latch 562 a near the driver's side end portion of the rear support bow of the middle panel retracted from catch 564 a secured to the lip of the side rail;
- FIG. 7 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 wherein the rear panel has been rotated forward onto the middle panel in a further step toward folding up the cover assembly;
- FIG. 7 B is a partial section view as seen from the line 7 B- 7 B of FIG. 7 A showing the engaging portion of the swing latch 562 a disengaged from the catch 564 a;
- FIG. 7 C is a schematic illustration similar to that shown in FIG. 5 C showing the alternate hinge body of FIG. 5 B but with the hinge body folded about 180 degrees as shown in the configuration illustrated in FIGS. 7 A- 7 B ;
- FIG. 8 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 , wherein the rear panel is folded over onto the middle panel and wherein both panels have been lifted up and pivoted forward generally about 90 degrees with respect to the front panel that is resting on the side rails and is generally in a horizontal plane with respect to the pickup truck shown in part in phantom;
- FIG. 8 B is a partial section view as seen from the line 8 B- 8 B of FIG. 8 A showing the swing latch 562 c near the driver's-side end portion of the support bow of the spacer panel disengaged from the corresponding catch 564 c;
- FIG. 8 C is a side view as seen from the line 8 C- 8 C of FIG. 8 A , but illustrating the rear panel together with the middle panel engaged top surface to top surface as shown in FIG. 8 A , but showing the two panels rotated forward further than shown in FIG. 8 A to the point that the standoff 558 touches the front panel 536 c;
- FIG. 8 D is a side view similar to FIG. 8 C , except that the rear panel together with the middle panel are rotated further forward so that the standoff is touching the front panel and the spacer panel is lifted up and rotated partially forward;
- FIG. 8 E is a side view similar to FIG. 8 D , except that the rear panel together with the front panel are rotated still further forward and the standoff is touching the front panel and the spacer panel is lifted up further and rotated further forward;
- FIG. 8 F is a schematic illustration showing a transverse vertical cross section similar to that of FIGS. 5 C and 7 C , but showing the spacer panel and two adjacent alternate hinges of the folding tonneau cover assembly of the present invention, illustrating both of the alternate hinges in a partially folded configuration similar to the partially folded orientation shown in FIG. 8 D ;
- FIG. 9 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 showing the rear panel together with the middle panel and the spacer panel rotated forward so that the middle panel and the rear panel are resting together on the top of the front panel, with the spacer panel rotated upward generally at a 90 degree angle to the other panels in a fully folded orientation, but also showing the standoffs 558 resting on alternate protective films 574 shown only in FIGS. 2 A, 9 A, 10 A, and 10 B as an alternate element in those figures;
- FIG. 9 B is a partial section view as seen from the line 9 B- 9 B of FIG. 9 A illustrating the driver's side of the completely folded tonneau cover assembly showing the rear support bow of the front panel resting on the lip of the driver's side side rail;
- FIG. 10 A is a front perspective view of the folding tonneau cover apparatus of FIG. 1 wherein the rear panel together with the middle panel and the spacer panel have been pivoted or rotated forward so that the middle panel and the rear panel are resting on the top surface of the front panel as in FIG. 9 A and showing the alternate protective film on the front panel engaged by the standoff 558 which rests on the protective film 574 ;
- FIG. 10 B is a front perspective view of the folding tonneau cover apparatus of FIG. 1 similar to the view of FIG. 10 A , but showing the storage strap 543 a pulled down and a strap bracket 543 b engaged with a bracket slot 543 c on the front edge of the front panel, securing the folding tonneau cover assembly 530 in the fully folded up configuration;
- FIG. 10 C is a front view of the folding tonneau cover apparatus of FIG. 1 showing a storage strap toward each side of the folded tonneau cover, with each storage strap pulled down and a strap bracket engaged with a bracket slot on the front edge of the front panel, securing the folding tonneau cover in the folded up configuration;
- FIG. 10 D is a side view from the driver's side of the folding tonneau cover apparatus of FIG. 1 in the configuration of FIG. 10 C further showing the fully folded configuration and schematically illustrating the flexible hinges in the folded-up configuration, with one of the storage straps being visible and a strap bracket engaged with a bracket slot on the front panel, securing the folding tonneau cover in the fully folded up configuration;
- FIG. 10 E is a schematic illustration showing a transverse vertical cross section similar to that of FIG. 8 F , showing the a spacer panel and two adjacent hinges of the folding tonneau cover of FIG. 1 , illustrating both of the alternate hinges in a 90-degree folded configuration;
- FIG. 11 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 1 viewed from slightly below and to the driver's side of the folding tonneau cover apparatus, wherein the folding tonneau cover assembly is secured in the fully folded up configuration similar to that of FIGS. 10 B- 10 D , showing a release cord for pulling the latches on the front panel against the bias of the springs to release the latches and schematically illustrating the flexible hinges in a manner similar to that in FIG. 10 D ;
- FIG. 11 B is a partial view of the portion of the folding tonneau cover apparatus of FIG. 1 shown in the dashed rectangle 11 B of FIG. 11 A , illustrating clip cord guides and a retainer cord guide and a corresponding release cord along a support bow, with the support bow shown in phantom to reveal the underlying structures;
- FIG. 12 illustrates the folding tonneau cover assembly 530 of FIG. 1 , secured in the fully folded up configuration disengaged from the support frame assembly 518 and being held in the arms of an operator;
- FIG. 13 A illustrates a clip cord guide aligned for attachment to a support bow or support member
- FIG. 13 B illustrates the clip cord guide of FIG. 13 A inserted into a channel of the support bow
- FIG. 13 C illustrates the clip cord guide of FIGS. 13 A and 13 B rotated so that an oblong securement feature engages the clip cord guide within the channel of the support bow;
- FIG. 13 D illustrates a retainer cord guide secured to a support bow
- FIG. 14 A is a perspective view illustrating a standoff
- FIG. 14 B is a side view illustrating the standoff of FIG. 14 A with longitudinal groove 558 b engaged with a sidebar 559 secured to the bottom surface of the rear panel 536 a and showing the support bow in phantom;
- FIG. 14 C is a side view illustrating the standoff of FIGS. 14 A and 14 B pivoted upward so that the longitudinal groove 558 c is engaged with the sidebar as shown and illustrating a standoff distance between a top of the protective pad on the standoff and the top surface of the rear panel and showing the support bow in phantom;
- FIG. 15 A illustrates a preferred perimeter seal in a transverse vertical cross section
- FIG. 15 B illustrates an alternate perimeter seal in a transverse vertical cross section
- FIG. 15 C illustrates a further alternate perimeter seal in a transverse vertical cross section
- FIG. 15 D illustrates another alternate perimeter seal in a transverse vertical cross section
- FIG. 15 E illustrates another alternate perimeter seal in a transverse vertical cross section
- FIG. 15 F illustrates a rigid panel edge guard in a transverse vertical cross section
- FIG. 15 G illustrates a still further alternate perimeter seal in a transverse vertical cross section
- FIG. 15 H illustrates a further alternate perimeter seal in a transverse vertical cross section
- FIG. 16 A illustrates a front view of a support bow or support member
- FIG. 16 B illustrates an alternate support bow similar to the support bow of FIG. 16 A , but wherein the alternate support bow has a slight bend or deflection of the support bow making its upper surface curved downwardly at the ends;
- FIG. 16 C is an end view of the support bow of FIG. 16 B showing the deflection d;
- FIG. 16 D is a schematic illustration of a front view of a rigid panel 536 ′ of the folding tonneau cover of FIG. 1 ;
- FIG. 16 E is a schematic illustration of a rigid panel of FIG. 16 D after being attached to the support bow of FIG. 16 B , causing the panel to have a slight downwardly concave curvature reflecting the deflection of the alternate support bow of FIG. 16 B ;
- FIG. 16 F is a perspective view of a straight support bow or support member with no hinge support flange and no downward deflection;
- FIG. 16 G is a perspective view of a curved support bow or support member with no hinge support flange and a downward curvature or deflection;
- FIG. 16 H is a perspective view of a straight support bow with one hinge support flange having a lip;
- FIG. 16 I is a perspective view of a curved support bow having a downward deflection and one hinge support flange having a lip;
- FIG. 16 J is a perspective view of a straight support bow having two hinge support flanges
- FIG. 16 K is a perspective view of a curved support bow having two hinge support flanges and a downward deflection
- FIG. 17 A is a cross sectional detail view as seen from the line 17 A- 17 A in FIG. 3 A , showing additional details in the vicinity of the side of the spacer panel, and showing two flexible hinges, a latch, a containment bracket, a hook, and a catch;
- FIG. 17 B is a cross sectional detail view similar to the view shown in FIG. 17 A , but with one of the flexible hinges folded up from the side rail, similar to the configuration of FIG. 8 A ;
- FIG. 17 C is a perspective view of a hinge body of the folding cover assembly of FIG. 1 shown isolated and in an unfolded configuration;
- FIG. 17 D is a perspective view of a portion of the hinge body including a transverse vertical cross sectional view of the hinge body taken from the dashed rectangle 17 D shown in FIG. 17 C ;
- FIG. 17 E is a view that is similar to the view shown in FIG. 17 D , except that the hinge body that is shown is an alternate hinge body;
- FIG. 17 F is a view that is similar to the view shown in FIG. 17 D , except that the hinge body that is shown is an alternate hinge body;
- FIG. 17 G is an enlarged schematic illustration similar to that shown in FIG. 18 J , which is referenced herein below, except that the hinge body is different which allows the configuration of the partial enclosure 592 to engage the alternate hinge body 545 a ′′′ in a slightly different manner wherein the panel 336 does not abut against the hinge body 545 a ′′′ the same way that is shown in FIG. 18 J ;
- FIG. 17 H is a further enlargement of a portion of the hinge body 545 a ′′′ and the partial enclosure 592 in which the hinge body is secured and also showing the gap 590 between a first point 593 a on the lip 587 b of the flange 586 b of the support bow 550 and a second point 593 b at the lower corner of the panel 536 which is taken from the dashed circle 17 H of FIG. 17 G ;
- FIG. 18 A is a schematic illustration similar to that of FIG. 5 A , but illustrating an alternative embodiment of the support bows each having a flange, but neither of which have a flange lip;
- FIG. 18 B is a schematic illustration similar to that of FIG. 5 A , but illustrating an alternative embodiment of the hinge body 545 a ′ having a single hinge body polymer material and having support bows that have a lip at the end of each of the support flanges of the partial enclosure;
- FIG. 18 C is a schematic illustration similar to that of FIG. 18 B , but illustrating a further alternative embodiment of the hinge body 545 a ′′ made of a single polymeric material and having a flat central portion;
- FIG. 18 D is a schematic illustration similar to that of FIG. 18 B , but illustrating a further alternative embodiment of the hinge body 545 a ′′′ made of a single polymeric material that is secured on each side within a partial enclosure created by the panel 536 and the support bow 550 without an adhesive securing the side portion to the rigid panel;
- FIG. 18 E is an enlarged schematic perspective illustration similar to that of FIG. 17 G , but with the hinge body shown partially secured within a partial enclosure 592 created by rigid panels 536 , one of which is partially broken away, and support bows having a lip at the end of each of the support flanges of the partial enclosure;
- FIG. 18 F is an enlarged schematic perspective view of the portion of FIG. 18 E shown in the dashed circle 18 F, but with the rigid panels and support bows shown only in part;
- FIG. 18 G is a further schematic perspective view similar to FIG. 18 E but showing the structure of the partial enclosure 592 with the hinge body shown only partially in phantom, with the rigid panels and support bows shown in cooperation with one another as shown in FIG. 18 D ;
- FIG. 18 H is an enlarged view providing a transverse vertical cross section of the portion of the folding tonneau cover assembly shown in FIG. 18 A , but showing the hinge body 545 a in phantom;
- FIG. 18 I is an enlarged view similar to that shown in FIG. 18 H , except that the hinge body 545 a is shown in cross section and the rigid panels 536 and the support bows 550 are shown in phantom;
- FIG. 18 J is an enlarged view of the portion of the folding tonneau cover assembly 530 shown in the dashed circle 18 J of FIG. 18 I ;
- FIG. 19 A is a detail side view of a portion of the folding tonneau cover apparatus of FIG. 1 as viewed from line 19 A — 19 A as indicated in FIG. 3 A , with the side rail on the driver's side in phantom and the truck removed to show the underlying structure, and showing in phantom an alternate position of the same portion of the folding tonneau cover apparatus in which the rear panel has been lifted up and rotated frontward somewhat so that the hook is disengaged from the catch;
- FIG. 19 B is a detail side view similar to that of FIG. 19 A , but in which the rear panel has been rotated completely forward onto the middle a panel;
- FIG. 19 C is a schematic illustration of steps and configurations of the folding tonneau cover apparatus of FIG. 1 showing the folding cover assembly being installed onto the side rails, showing the hooks at the front of the front panel approaching the catches at the front of the side rails, then the hooks at the front of the front panel engaged with the catches at the front of the side rails and the latches at the rear of the front panel engaged with the side rails and the respective containment brackets, then the spacer panel and middle panel unfolded with the hooks at the front of the middle panel engaged with the respective catches on the side rails, then the rear panel unfolded with the hooks at the front of the rear panel engaged with the respective catches on the side rails and the latches at the rear of the rear panel engaged with the respective side rails and containment brackets;
- FIG. 20 A is a schematic illustration of the folding tonneau cover apparatus of FIG. 1 , as configured for a cargo box having angled sides;
- FIG. 20 B is a schematic illustration of the folding tonneau cover apparatus of FIG. 1 , as configured for a cargo box having parallel sides;
- FIG. 20 C is a schematic illustration of the folding tonneau cover apparatus of FIG. 1 , as configured for an elongated cargo box;
- FIG. 20 D is a schematic illustration of the folding tonneau cover apparatus of FIG. 1 , as configured for a shorter cargo box;
- FIG. 20 E is a schematic illustration of the folding tonneau cover apparatus of FIG. 1 , as configured for a cargo box with arbitrary shape;
- FIG. 21 A is a schematic illustration of a portion of the folding tonneau cover apparatus of FIG. 1 , illustrating a flexible hinge interconnecting two adjacent panels, showing bent or bowed support bows creating a bending or bowing of the panels attached thereto (see also FIGS. 16 B- 16 E, 16 G, 16 I, and 16 K ), with the bending or bowing exaggerated for illustration, with the panels unfolded; and
- FIG. 21 B is a schematic illustration similar to that of FIG. 21 A , showing the panels folded up, and together with FIG. 21 A illustrating how the flexible hinge can accommodate the folding up and unfolding of such bent or bowed panels.
- FIG. 22 is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus having a folding cover assembly incorporating a cab panel onto which rear, middle, spacer, and front panels can fold, with the folding tonneau cover apparatus attached to a pickup truck which is shown in phantom, but for clarity of illustration the perimeter seal is not shown;
- FIG. 23 is a bottom plan view of the folding tonneau cover apparatus of FIG. 22 ;
- FIG. 24 is a partial section view of the rear portion of the folding tonneau cover apparatus of FIG. 22 as indicated on FIG. 23 and illustrating an edge guard at the rear portion of the rear panel;
- FIG. 25 A is schematic illustration of a cross section along a front-back plane of one of the hinges of the folding tonneau cover of FIG. 22 showing the basic configuration with the hinge unfolded;
- FIG. 25 B is a schematic illustration of a cross section along a front-back plane of a preferred embodiment of one of the hinges of the folding tonneau cover of FIG. 22 showing the hinge unfolded;
- FIG. 25 C is a schematic illustration showing the hinge of FIG. 25 B but with the hinge folded about 45 degrees;
- FIG. 26 is a schematic illustration showing the hinge of FIG. 25 B but with the hinge folded about 180 degrees;
- FIG. 27 is a schematic illustration showing a cross section similar to that of FIG. 25 C showing a spacer panel and two adjacent hinges of the folding tonneau cover of FIG. 22 , illustrating both hinges in a partially folded configuration;
- FIG. 28 is a schematic illustration showing the general steps and configurations of the folding cover assembly of FIG. 22 as it is folded up;
- FIG. 29 is a side perspective view from the driver's side of the folding tonneau cover apparatus of FIG. 22 , showing a configuration in which the rear, middle, and spacer panels are folded onto the front panel and secured with storage straps, but for clarity of illustration the perimeter seal is not shown;
- FIG. 30 is a side perspective view similar to that of FIG. 29 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically, but for clarity of illustration the perimeter seal is not shown;
- FIG. 31 A is a side perspective view similar to that of FIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including cab straps, but for clarity of illustration the perimeter seal is not shown;
- FIG. 31 B is a side perspective view similar to that of FIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a side strap, but for clarity of illustration the perimeter seal is not shown;
- FIG. 31 C is a side perspective view similar to that of FIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a cab panel strap, but for clarity of illustration the perimeter seal is not shown;
- FIG. 31 D is a side perspective view similar to that of FIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a securing magnet, but for clarity of illustration the perimeter seal is not shown;
- FIG. 31 E is a side perspective view similar to that of FIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a securing bracket, but for clarity of illustration the perimeter seal is not shown;
- FIG. 32 is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus according to the present invention, including a support frame assembly, a folded cover forward securing assembly, and a folding cover assembly incorporating a cab panel onto which rear, middle, spacer, and front panels can fold, with the folding tonneau cover apparatus attached to a pickup truck which is shown in phantom;
- FIG. 32 A is a top plan view primarily showing the folding cover assembly shown in FIG. 32 ;
- FIG. 32 B is a bottom plan view primarily showing the folding cover assembly of FIG. 32 ;
- FIG. 32 C is a side view of portions of the folding tonneau cover apparatus of FIG. 32 as viewed from line 32 C- 32 C of FIG. 32 A ;
- FIG. 32 D is a detailed view of a portion of the folding tonneau cover apparatus as viewed from line 32 D- 32 D of FIG. 32 A , illustrating the spacer panel and adjacent hinges;
- FIG. 32 E is a detailed view of a portion of the folding tonneau cover apparatus as viewed from line 32 E- 32 E of FIG. 32 A , illustrating the rear hinge;
- FIG. 32 F is an enlarged detailed front perspective view of a portion of the folding tonneau cover apparatus encircled by dashed line 32 F- 32 F of FIG. 32 C , showing a storage retainer and a tether and link;
- FIG. 32 G is a side view of the storage retainer shown in FIG. 32 F ;
- FIG. 32 H is a bottom perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 ;
- FIG. 32 I is an enlarged perspective bottom view of the portion of the folding tonneau cover apparatus encircled by the dashed line 32 I of FIG. 32 H , illustrating the spacer panel and adjacent hinges and showing a brace retained in a brace retainer;
- FIG. 32 J is an enlarged perspective bottom view of the portion of the folding tonneau cover apparatus encircled by the dashed line 32 J of FIG. 32 H , illustrating the cab panel and showing a rail clamp bracket and a hex clamp bolt;
- FIG. 32 K is an enlarged perspective bottom view similar to that of FIG. 32 J but illustrating an alternative lever clamp bolt
- FIG. 33 A is a rear perspective view a portion of the folding tonneau cover apparatus of FIG. 32 ;
- FIG. 33 B is a partial section view as seen from the line 33 B- 33 B of FIG. 33 A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom;
- FIG. 34 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 32 , with the release cord pulled to pull the latch against the bias of the spring to release the latch from the engagement with the side rail, with the two portions of the release cord pulled for illustration;
- FIG. 34 B is a partial section view as seen from the line 34 B- 34 B of FIG. 34 A similar to the view of FIG. 33 B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail;
- FIG. 35 A is schematic illustration of a vertical cross section along a front-to-back plane as seen from the line 35 A- 35 A of FIG. 32 A of one of the hinges of the folding tonneau cover assembly of FIG. 32 showing the basic configuration with the hinge unfolded;
- FIG. 35 B is a schematic illustration similar to FIG. 35 A of a transverse vertical cross section along a front-to-back plane showing an alternate embodiment of one of the hinges of the folding tonneau cover assembly of FIG. 32 showing the hinge unfolded;
- FIG. 35 C is a schematic illustration showing the hinge of FIG. 35 B , but with the hinge folded at about 45 degrees from the unfolded orientation shown in FIG. 35 B ;
- FIG. 35 D is a schematic illustration showing the general steps and configurations of the folding tonneau cover assembly of FIG. 32 as it is folded up into a fully folded orientation;
- FIG. 36 A is a rear perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 wherein the latches on the rear panel have been released as in FIG. 34 B and the rear panel has been lifted up in a first step toward folding up the folding cover assembly;
- FIG. 36 B is a partial section view as seen from line 36 B- 36 B of FIG. 36 A showing the latch near the driver's side end portion of the rear support bow of the middle panel engaged with the lip of the side rail;
- FIG. 37 A is a rear perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 wherein the rear panel has been rotated forward onto the middle panel in a further step toward folding up the cover assembly;
- FIG. 37 B is a partial section view as seen from the line 37 B- 37 B of FIG. 37 A showing the latch near the driver's side end portion of the rear support bow of the middle panel engaged with the lip of the side rail;
- FIG. 37 C is a partial section view similar to the view of FIG. 37 B , but showing the arrangement with the engaging portion of the latch retracted and disengaged from the lip of the side rail, allowing the middle panel to be lifted up;
- FIG. 38 A is a rear perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 , wherein the rear panel is folded over onto the middle panel and wherein both panels have been lifted up and pivoted forward generally about 90 degrees with respect to the front panel that is resting on the side rails and is generally in a horizontal plane with respect to the pickup truck shown in part in phantom;
- FIG. 38 B is a partial section view as seen from the line 38 B- 38 B of FIG. 38 A showing the swing latch 562 c near the driver's-side end portion of the support bow of the spacer panel disengaged from the corresponding catch 564 c;
- FIG. 39 A is a rear perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 showing the rear panel together with the middle panel and the spacer panel rotated forward so that the middle panel and the rear panel are resting together on the top of the front panel, with the spacer panel rotated upward generally at a 90 degree angle to the other panels;
- FIG. 39 B is a partial section view as seen from the line 39 B,C- 39 B,C of FIG. 39 A illustrating the driver's side of the partially folded tonneau cover assembly showing the engaging portion of the latch near the driver's-side end portion of the support bow of the front panel engaged with the lip of the driver's side side rail and a containment bracket;
- FIG. 39 C is a partial section view similar to the view of FIG. 39 B , but showing the arrangement with the engaging portion of the latch retracted and disengaged from the lip of the side rail, allowing the front panel to be lifted up;
- FIG. 39 D is a partial section view as seen from the line 39 D,E- 39 D,E of FIG. 39 A illustrating the driver's side of the partially folded tonneau cover assembly showing a storage strap;
- FIG. 39 E is a partial section view similar to the view of FIG. 39 D showing the storage strap engaged with a storage retainer to secure the rear, middle, and spacer and front panels to the cab panel;
- FIG. 40 illustrates the folding tonneau cover apparatus of FIG. 32 , including the folding cover assembly secured in the fully folded-up configuration with two cab braces each engaged with a cab bracket secured to the truck cab; an operator can attach or detach the cab braces from the cab brackets, or actuate the hex bolts or handle bolts to disengage the folding cover assembly from the side rails to remove the folding cover assembly from the support frame assembly or attach the folding cover assembly to the support frame assembly as desired;
- FIG. 40 A is a side perspective view of a portion of the tonneau cover apparatus of FIG. 32 showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically;
- FIG. 40 B is a side perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 similar to the view of FIG. 40 A , but showing two cab braces each engaged with a cab bracket to hold the folded up tonneau cover assembly in a generally vertical configuration adjacent the truck cab (shown in phantom);
- FIG. 40 C is a perspective view of a portion of the folding cover assembly showing the spacer panel and adjacent hinges and a support bow having a cab brace secured to the support bow for storage;
- FIG. 40 D is a perspective view similar to that of FIG. 40 C but with the cab brace rotated outward so that it can be secured to a cab bracket;
- FIG. 40 E is a side perspective view of a portion of the folding tonneau cover apparatus of FIG. 32 similar to the view of FIG. 40 B , but including an auxiliary support bow to which the two cab braces are attached, and showing the two cab braces each engaged with a cab bracket assembly to hold the folded up tonneau cover assembly in a generally vertical configuration adjacent the truck cab (shown in phantom);
- FIG. 40 F is an exploded perspective view of a portion of the cab bracket assembly shown in FIGS. 40 B, 40 E , and elsewhere herein;
- FIG. 40 G is a section view as seen from line G-G of FIG. 40 F showing a cab bracket body
- FIG. 40 H is a perspective view of the cab bracket assembly of FIG. 40 F also showing a cab bracket adhesive
- FIG. 41 is a rear perspective view of an alternate embodiment of folding or hinged tonneau cover apparatus according to the present invention, including a support frame assembly and a folding or hinged cover assembly, with the hinged tonneau cover apparatus attached to a pickup truck which is shown in phantom;
- FIG. 42 A is a top plan view showing the hinged cover assembly of in FIG. 41 ;
- FIG. 42 B is a bottom plan view primarily showing the hinged cover assembly of FIG. 41 and showing retainer bolts which are handle bolts;
- FIG. 42 C is a side view of portions of the hinged tonneau cover apparatus of FIG. 41 as viewed from line 42 C- 42 C of FIG. 42 A ;
- FIG. 42 D is an enlarged detailed view of a portion of the hinged tonneau cover apparatus encircled by dashed line 42 D- 42 D of FIG. 42 C ;
- FIG. 42 E is a bottom perspective view of a portion of the hinged tonneau cover apparatus of FIG. 41 ;
- FIG. 42 F is a detail bottom perspective view of the portion of the hinged cover assembly of FIG. 41 encircled by dashed line 42 F- 42 F of FIG. 42 E ;
- FIG. 42 G is a partial section view as seen from the line 42 G- 42 G of FIG. 42 A illustrating the driver's side of the hinged tonneau cover apparatus;
- FIG. 42 H is a bottom plan view of an alternate hinged tonneau cover apparatus showing an alternate hinged cover assembly similar to that shown in FIG. 41 but having retainer bolts which are hex bolts;
- FIG. 42 I is a detail bottom perspective view similar to FIG. 42 F but of a portion of the hinged cover assembly of FIG. 42 H , showing one of the hex bolts and a hinge support;
- FIG. 43 A is a rear perspective view of the hinged cover assembly of FIG. 42 H , with the hinged tonneau cover apparatus attached to a pickup truck which is shown partially and in phantom;
- FIG. 43 B is a partial section view as seen from the line 43 B- 43 B of FIG. 43 A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail, and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom;
- FIG. 44 A is a rear perspective view of the folding tonneau cover apparatus of FIG. 42 H similar to the view of FIG. 43 a , but with a release cord pulled to pull the latch to release the latch from the engagement with the side rail, with two portions of the release cord pulled for illustration;
- FIG. 44 B is a partial section view as seen from the line 44 B- 44 B of FIG. 44 A similar to the view of FIG. 43 B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail;
- FIG. 45 is an enlarged detailed view of the portion of the hinged tonneau cover apparatus of FIG. 42 H similar to that shown in FIG. 42 D , except that some parts have been removed to reveal underlying structures including a hinge support, and the rear panel has been lifted up about 30 degrees;
- FIG. 46 is an enlarged detail side view of the hinge support of FIG. 45 ;
- FIG. 47 is a perspective view of the hinge support of FIG. 45 ;
- FIG. 48 is a rear perspective view of the hinged tonneau cover apparatus of FIG. 42 H with the cover partially lifted up to access the cargo box.
- a folding tonneau cover apparatus 510 of the present invention is attachable to sidewalls 6 a , 6 b of a cargo box 5 , such as the cargo box of a truck or pickup truck 2 , which is shown in phantom.
- the folding tonneau cover apparatus 510 is shown in a typical application covering the top opening 6 f (shown in phantom in FIG. 12 ) of the cargo box 5 of the pickup truck 2 .
- the pickup truck 2 and the cargo box 5 and the sidewalls 6 a and 6 b and the front wall 6 c FIG.
- the perimeter of the cargo box 5 includes the forward end or front wall 6 c , the opposing sidewalls 6 a and 6 b , and the rearward end or tailgate 6 d , which is shown in part.
- the rearward end or tailgate 6 d preferably can be opened or closed.
- the folding tonneau cover apparatus 510 includes a folding tonneau cover assembly, tonneau cover assembly or cover assembly 530 and a support frame assembly 518 , including side rails or rails 520 a and 520 b .
- side rails 520 a and 520 b are secured to sidewalls 6 a and 6 b with clamps 514 .
- the folding cover assembly 530 is configured to be opened to an open position and closed to a closed position, and easily removed and reinstalled by a driver or other operator 8 ( FIG. 12 ), as needed.
- the side rails 520 a and 520 b are constructed and arranged to facilitate securement of the folding cover assembly 530 to the side rails 520 a and 520 b .
- the side rails 520 a and 520 b have a side rail lip 524 and a side rail engagement portion 522 a .
- clamps 514 there are eight clamps 514 arranged to hold the side rails 520 a and 520 b to the sidewalls 6 a , 6 b of the pickup truck 2 , but other numbers of clamps 514 can be used.
- the clamps include an outer member 516 a , an inner member 516 b , a clamp engagement portion 516 c , and a fastener assembly 516 d ; the fastener assembly can, for example, include a bolt 516 e , a washer 516 f and a nut 516 g as illustrated.
- FIG. 2 A shows a top view of the folding tonneau cover assembly 530 of FIG. 1 .
- the top 532 a of the folding cover assembly 530 is shown.
- the folding cover assembly 530 includes rigid panels or panels 536 .
- panels 536 include a rear panel 536 a , a middle panel 536 b , a front panel 536 c , and a spacer panel or hinge panel 536 d .
- panels 536 are specifically referenced herein as 536 a - 536 d , and non-specifically or collectively referenced as rigid panels 536 .
- the folding cover assembly 530 includes a plurality of such rigid panels 536 , and could potentially have from two to 8 panels 536 ; for example, 6 panels 536 could be used, including 4 “longer” panels (similar to panels 536 a - 536 c shown herein) and 2 “shorter” panels (similar to panels 536 d shown herein). While a smaller or a larger number of panels 536 can be used (not shown), the inventors have found that the configurations illustrated herein provide a good trade-off of convenient folded configuration vs. complexity.
- the length 539 of each of the panels 536 a - 536 d is indicated as 539 a - 539 d , respectively.
- the spacer panel 536 d has a substantially smaller length 539 d than the other panels, as will be further described herein.
- the length 539 d of the spacer panel 536 d is preferably no greater than about one-third of the length 539 a - 539 c of the other panels 536 a - 536 c .
- Panels 536 a - 536 d can have similar length 539 , or the length of some or all of panels 536 a - 536 d can differ.
- the width 540 of each of the panels 536 a - 536 d is indicated as 540 a - 540 d , respectively.
- Panels 536 a - 536 d can have the same width 540 , or the width of some or all of panels 536 a - 536 d can differ.
- the side angle 542 of each of the panels 536 a - 536 d is indicated as 542 a - 542 d , respectively, in FIG. 20 A .
- Panels 536 a - 536 d can have the same side angle 542 , or the side angle 542 of some or all of panels 536 a - 536 d can differ.
- Alternative configurations of folding tonneau covers 530 appropriate for covering the cargo box 5 of various models of pickup truck 2 are further described below.
- Each panel 536 has a top surface 537 and a bottom surface or underside 538 ;
- panel 536 a has a top surface 537 a and a bottom surface or underside 538 a
- panel 536 b has a top surface 537 b and a bottom surface or underside 538 b
- panel 536 c has a top surface 537 c and a bottom surface or underside 538 c
- panel 536 d has a top surface 537 d and a bottom surface or underside 538 d.
- the present invention includes a folding tonneau cover assembly 530 having a plurality of rigid panels 536 arranged in a series, with adjacent rigid panels 536 secured to each other by a flexible hinge 544 , so that the folding cover tonneau cover assembly 530 can be unfolded to cover a top opening 6 f ( FIG. 12 ) of a cargo box 5 of a truck 2 , and folded up to uncover at least a portion of the top opening 6 f of the cargo box 5 of the truck 2 .
- Each rigid panel 536 has a front edge 541 b and a rear edge 541 c and a driver's side edge 541 d and a passenger side edge 541 e and a top surface 537 and a bottom surface or underside 538 .
- each of the rigid panels 536 extends between the driver's side 3 a and the passenger side 3 b of the cargo box 5
- each flexible hinge 544 extends between the driver's side and the passenger side of the cargo box.
- there are 3 flexible hinges 544 each flexible hinge 544 being secured to two adjacent rigid panels 536 .
- embodiments having two rigid panels 536 and one flexible hinge 544 including embodiments having two rigid panels 536 and one flexible hinge 544 , embodiments having three rigid panels 536 and two flexible hinges 544 , embodiments having five rigid panels 536 and four flexible hinges 544 , embodiments having six rigid panels 536 and five flexible hinges 544 , and so forth.
- the number of rigid panels 536 is 1 greater than the number of flexible hinges 544 ;
- alternative embodiments include folding tonneau cover assemblies 530 having at least three rigid panels 536 and at least one flexible hinge 544 , as described herein, and at least one other hinge or connection as may be known in the art (not shown) have been envisioned by the inventors.
- the present invention includes such embodiments, as long as the embodiments include at least one flexible hinge 544 as described herein.
- FIG. 2 A Also illustrated in FIG. 2 A , is a protective film 574 on the top surface 537 c of the front panel 536 c .
- alternate embodiments of the folding tonneau cover assembly 530 include the protective film 574 , which protects the top surface 537 c of the front panel 536 c when the folding tonneau cover assembly 530 is folded up and the standoffs 558 are in contact with the top surface 537 c .
- a protective pad 558 a is preferably attached to the bottom of each standoff 558 , but abrasion of the top surface 537 c can occasionally occur when the protective pads 558 a are in direct contact with the top surface 537 c , especially when the pickup truck on which the folding cover assembly 530 resides is travelling on rough road surfaces that cause the protective pads 558 a to vibrate on the top surface 537 c .
- the protective film 574 is optional to reduce or prevent such abrasion in some embodiments, they are not required.
- Such alternate embodiments of the present invention, which include the protective film 574 to minimize abrasive damage to the top surface 537 c are disclosed herein.
- Protective film 574 can be obtained from a variety of suppliers, including Avery Dennison (Glendale, Calif.), 3M (St. Paul, Minn.), Arlon (Placentia, Calif.), and Xpel (San Antonio, Tex.).
- One preferred protective film 574 is Avery Dennison SW 900 Series Supreme Wrapping Film.
- the protective film 574 is preferably applied to specific locations on the top surface 537 c which will align with the standoffs 558 when the folding tonneau cover assembly 530 is folded up as shown and described herein. For example, for embodiments including 4 standoffs 558 , protective film can be applied to the top surface 537 c in the locations shown in FIG. 2 B .
- the protective film 574 is preferably located in locations on the top surface 537 c as schematically illustrated on FIG. 2 A that correspond to the locations that the protective pads 558 a of the standoffs 558 will assume when they engage the top surface 537 c of the front panel 536 c , when the folding cover assembly 530 is in a fully folded up orientation.
- FIG. 2 B shows a bottom view of the folding tonneau cover apparatus 510 .
- hinges or flexible hinges 544 which are situated between adjacent panels 536 and adjoin adjacent panels 536 .
- hinges 544 are specifically referenced herein as 544 a - 544 c , and non-specifically or collectively referenced as 544 .
- situated between the rear panel 536 a and the middle panel 536 b is hinge 544 a .
- hinge 544 b situated between the middle panel 536 b and the spacer panel 536 d
- situated between the spacer panel 536 d and the front panel 536 c is hinge 544 c .
- Hinges 544 allow the folding cover assembly 530 to be folded up and will be more fully described below.
- Support bows 550 are attached to the panels 536 to provide additional support and rigidity to the panels 536 , and also provide a structure for mounting of various other components as described in detail later herein.
- support bows 550 are specifically referenced herein as 550 a - 550 g , and non-specifically or collectively referenced as 550 .
- the folding tonneau cover assembly 530 is removably secured to the support frame assembly 518 by securing apparatus 551 a .
- securing apparatus 551 a includes at least one locking member 551 b which is engageable and disengageable from the support frame assembly 518 .
- the locking member 551 b includes latches 552 which are located at the support bows as shown and secure the folding cover assembly 530 to the side rails 520 a and 520 b .
- Release cords 554 are attached to the latches 552 .
- latches 552 are specifically referenced herein as 552 a - 552 d , and non-specifically or collectively referenced as 552 .
- release cords 554 are specifically referenced herein as 554 a - 554 b , and non-specifically or collectively referenced as 554 .
- the release cords 554 pass through cord guides 555 which are attached to support bows 550 as shown.
- Cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b , which will be described in further detail below.
- Standoffs 558 are shown, and will be described in further detail below.
- Sidebars or handles 559 are attached to panels 536 a , 536 b , and 536 c , near each side of each panel 536 to further support the panels 536 .
- Perimeter seal 534 is located on the bottom 532 b of the folding cover assembly 530 and is arranged to seal against top of the perimeter of the cargo box 5 at the sidewalls 6 a and 6 b and the front wall 6 c and the tailgate 6 d of the cargo box 5 as shown; some portions of perimeter seal 534 are behind side rails 520 a and 520 b and not visible FIG. 2 B .
- the perimeter seal 534 is further described herein.
- the support bows or transverse frame members or channels 550 provide additional support for the panels 536 .
- the panels each have two support bows 550 , one located near each of the front and rear ends of each panel 536 , except for the spacer panel 536 d , which has only a single support bow 550 .
- the latches 552 engage the side rails 520 a and 520 b to secure the folding cover assembly 530 , and can slide a short distance towards or away from the side rails 520 a and 520 b to engage or release the folding cover assembly 530 or portions thereof or selected panels 536 from the side rails 520 a and 520 b as further described below.
- the support bows 550 b , 550 c , 550 d , 550 e , and 550 g do not have associated latches 552 in this embodiment.
- latch release cords or release cords or cords 554 there are two latch release cords or release cords or cords 554 , each of which are connected to opposing pairs of latches 552 which secure the panels 536 to the side rails 520 a and 520 b .
- the release cords 554 preferably pass through cord guides 555 which are mounted to the support bows 550 ; the release cords 554 can slide within or behind the cord guides 555 as further described herein.
- the release cords 554 generally extend from the latches 552 along the support bows 550 .
- the clamps 514 secure the side rails 520 a and 520 b to the sidewalls 6 a and 6 b of the cargo box 5 .
- the folding tonneau cover apparatus 510 is seen in a side view from the driver's side in FIG. 2 C .
- the portion of the folding tonneau cover apparatus 510 that includes the middle and front hinges 544 b and 544 c , respectively, as indicated by the encircled area labeled 2 E in FIG. 2 C is illustrated in an enlarged partial cutaway view in FIG. 2 E .
- the folding cover assembly 530 preferably includes extended hinge support flange(s) 586 located adjacent the bottom surface or underside 538 of the respective panel 536 and near the front and rear edges 541 b and 541 c , respectively, of the rigid panels 536 to which the flexible hinges 544 are secured (for example, FIG. 5 A ).
- the flexible hinges 544 each preferably includes a flexible hinge body 545 a which includes a central portion 546 a , side portions 546 b and 546 c , and intermediate portions 546 d and 546 e .
- Each side portion 546 b and 546 c preferably extends between the extended hinge support flange 586 and the rigid panel 536 .
- Adhesive 570 a is preferably located between each side portion 546 b and the respective rigid panel 536 to protect against passage of debris or precipitation into the cargo box 5 ; the adhesive 570 a can also aid in securement of the hinge body 545 a to the respective rigid panel 536 .
- the support bows or channels 550 are preferably secured to the bottom surface or underside 538 of the rigid panels 536 , near the front edge 541 b and/or rear edge 541 c of the rigid panels 536 .
- Each support bow 550 that is adjacent a flexible hinge 544 preferably includes the extended hinge support flange 586 . Further details regarding the structure of the flexible hinge body 545 a and securement to the rigid panels 536 are described below.
- the folding tonneau cover apparatus 510 preferably includes containment brackets 525 a and 525 b .
- the structure and function of the containment bracket 525 a is further illustrated in FIG. 2 F . Note that in FIG. 2 F , portions of the rigid panels 536 and the flexible hinges 544 are broken away to reveal the underlying structure, and many elements are illustrated in phantom to emphasize the elements being described.
- the engaging portion 553 b is engaged under the side rail 520 a and is contained by the containment bracket or anchor socket 525 a as illustrated in FIG. 2 F , the engaging portion 553 b is contained by the containment bracket 525 a so that it cannot slide frontwards or rearwards along the side rail 520 a .
- the containment bracket 525 a is preferably secured to the side rail by a fastener assembly 526 , which may include a bolt, nut, washer, or other fasteners known in the art.
- a fastener assembly 526 which may include a bolt, nut, washer, or other fasteners known in the art.
- the spring 556 is urging the latch slide 553 outwards towards the side rail 520 a .
- the release cord 554 e is pulled.
- the side rail 520 b preferably has a mirror-image configuration to the side rail 520 a , with a side rail front portion 521 c and side rail rear portion 521 d , and a containment bracket 525 b functioning in a similar manner.
- Some embodiments include the alternative side rail 520 c which includes a plurality of sections 521 as illustrated in FIG. 2 G ; the side rail 520 c preferably includes side rail front portion 521 a and side rail rear portion 521 b .
- the containment bracket 525 a is preferably secured to the side rail 520 c by a fastener assembly 526 , which may include a bolt 516 e , nut 516 f , washer 516 g , or other fasteners known in the art.
- the containment bracket 525 a in addition to its function to retain the latch 552 as previously described, the containment bracket 525 a preferably facilitates securement of the side rail front portion 521 a and side rail rear portion 521 b together.
- the side rail 520 d preferably has a mirror-image configuration to the side rail 520 c , with a side rail front portion 521 c and side rail rear portion 521 d , and a containment bracket 525 b functioning in a similar manner as the similar elements just described.
- the alternative side rail 520 c , containment bracket 525 a , and fastener assembly 526 are illustrated in exploded view in FIG. 2 H .
- a tether 580 is attached to the containment bracket 525 b and is releasably secured by a link 581 when desired to a ring 582 that is secured to the support bow 550 e ; this arrangement provides additional stabilization of the folding cover assembly 530 when the folding cover assembly 530 is secured to the side rails 520 a , 520 b and will secure the folding cover assembly 530 to the side rail 520 if other attachments fail.
- the “driver's side” refers to the side corresponding to the side of the vehicle typically used by the driver to operate the vehicle in North America, and the “passenger side” refers to the side opposite the “driver's side”.
- the “length” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein refers to a measurement of the “front” to “rear” dimension, since the pickup truck and the cargo box are typically longer in that direction.
- “width” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein generally refers to the “driver's side” to “passenger side” direction, since the pickup truck and the cargo box are typically shorter in that direction.
- folding tonneau cover apparatus could be shorter in the “length” direction than in the “width” direction, for example.
- “length” has the normal meaning, referring to the longer dimension or to the dimension along an extruded shape, for example; any potential confusion in terminology can be eliminated by examination of the various Figures in the accompanying drawings.
- FIG. 3 B is an enlarged partial section view of the driver's side end portion of the support bow 550 a as indicated in FIG. 3 A .
- the cord guides 555 are preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer.
- the cord guides 555 can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process.
- One of the standoffs 558 can be seen in FIG. 3 A , and will be described in more detail later.
- the latch 552 includes latch slide 553 having an engaging portion 553 b which extends forward to engage the lip 524 of the side rail 520 a , so as to secure the respective panel 530 to the side rail 520 a .
- the latch slide 553 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used.
- the latch slide 553 includes fiberglass-reinforced nylon.
- the latch slide 553 is biased by a biasing member or spring 556 towards the side rail 520 a so that the engaging portion 553 b engages the side rail 520 a to form a secured configuration in which the respective panel 530 is restricted from being lifted up from the cargo box 5 ;
- the spring 556 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide 553 towards the side rail 520 a so that the engaging portion 553 b engages the side rail 520 a so that the latch 552 is in the secured configuration.
- the spring 556 is held between the latch slide 553 and a spring retainer assembly 557 .
- the spring retainer assembly 557 is secured in the desired location in the support bow 550 a .
- the side rails 520 a and 520 b preferably include extruded metal, and have a side rail engagement portion 522 a ( FIG. 3 B ), arranged to approximate a portion of the sidewall 6 a , 6 b of the pickup truck 2 .
- the clamp 514 is shown in detail in FIG. 3 B .
- the clamps 514 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.
- Clamps 514 preferably have an outer member 516 a and an inner member 516 b which are tightened towards each other and held as an assembly on the sidewall 6 a by a fastener assembly 516 d which preferably includes a bolt 516 e , a washer 516 f , and a nut 516 g .
- inner member 516 b has a clamp engagement portion 516 c which, together with side rail engagement portion 522 a of side rail 520 a , aids in securing the clamps 514 in place on the side rail 520 a .
- the clamps 514 are arranged and tightened to secure the side rail 520 a to the sidewall 6 a , with a sidewall gasket 522 c arranged between the side rail 520 a and the sidewall 6 a as illustrated.
- a bow end cap 565 is located at the end of the support bow 550 a .
- a release cord 554 and a cord guide 555 are shown, and will be described in further detail herein.
- the side rail engagement portion 522 a is a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of the sidewall 6 a , 6 b . In the example of FIG.
- FIGS. 4 B 6 B, 7 B, 8 B and 9 B a portion of the sidewall 6 a of a cargo box 5 of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a side rail engagement portion 522 a along the length of the side rails 520 a and 520 b that are appropriately configured and oriented.
- the cargo box 5 of the pickup truck 2 includes a sidewall cap 6 e , but other cargo boxes 5 lack a sidewall cap.
- a sidewall 6 a and sidewall cap 6 e are similarly illustrated in subsequent drawings herein, including FIGS. 4 B 6 B, 7 B, 8 B and 9 B.
- the side rail engagement portion 522 a has a side rail engagement feature 522 b , such as ridges, knurling, surface patterns or textures, or other features which aid in securing the clamps 514 .
- a sidewall gasket 522 c preferably made of polymeric material is located between the side rail engagement portion 522 a and the sidewall 6 a ; the sidewall gasket 522 c can provide protection against damage to the sidewall 6 a by abrasion against the side rail 520 a . Other flexible material can also be used.
- the sidewall gasket 522 c can provide leak resistance to prevent water, dust, or other debris from passing into the cargo box 5 along the side rail engagement portion 522 a .
- the side rail 520 a has a flange or side rail lip 524 along the length of the side rail 520 a .
- the side rail lip 524 provides support for the folding cover assembly 530 .
- the side rail lip 524 provides a feature for engagement of the engaging portion 553 b of the latches 552 .
- the driver's side portion of the support bow 550 a is shown in FIG. 3 B ; the other end of the support bow 550 a (toward the passenger side) has a mirror-image configuration, with a latch 552 engaging side rail 520 b , and side rail 520 b being attached to sidewall 6 b in a similar manner.
- the release cord 554 a can be pulled, which will retract each of the latches 552 against the force of the respective biasing member or spring 556 .
- the release cord 554 a will be pulled as illustrated in FIG. 4 A , by a driver (not shown) who has walked to the rear of the cargo box 5 and has opened the tailgate 6 d and reaches in to access and pull the release cord 554 a .
- the engaging portion 553 b of the latch 552 is retracted away from the lip 524 of the side rail 520 a as shown in FIG.
- the cord guides 555 adjacent to the latches 552 help to maintain alignment of the ends of the release cord 554 a so that the latches 552 are retracted in alignment with the support bow 550 a , to avoid excessive friction, wear and potential binding.
- the driver's side portion of the support bow 550 a is shown in FIG.
- the other end of the support bow 550 a (toward the passenger side) has a mirror-image configuration, and when the release cord 554 a is pulled, the latches 552 at both ends of the support bow 550 a are retracted, so that the rear end of the rear panel 536 a can be lifted up from both side rails 520 a and 520 b.
- each of the hinges 544 ( 544 a , 544 b , and 544 c ) preferably includes the flexible hinge body 545 a which is elongated and extends between the driver's side 3 a and the passenger side 3 b of the cargo box 5 when the folding cover assembly 530 is unfolded to cover the cargo box 5 .
- the flexible hinge body 545 a has a hinge longitudinal axis 545 b which is oriented along the length of the hinge body 545 a , and a hinge body profile 545 c , which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis 545 b .
- the hinge body profile 545 c is preferably uniform along the hinge longitudinal axis 545 b of the hinge body 545 a .
- each of the flexible hinges 544 can have a similar hinge body profile 545 c .
- the hinge body profile 545 c of the flexible hinge bodies 545 a can differ from the profile of at least one other of the flexible hinge bodies 545 a.
- the folding tonneau cover assembly 530 of the present invention may include one of several different hinge body embodiments 545 a , 545 a ′, 545 a ′′, 545 a ′′′ (see also FIGS. 17 C- 18 F ).
- the first embodiment 545 a shown in FIGS. 5 A- 5 C and FIGS.
- 17 A- 17 D is a dual durometer hinge having a more flexible polymer material 547 c making up the central portion 546 a and a portion of the intermediate portion 546 d , 546 e adjacent to and on each side of the central portion 546 a , and a more rigid or stiff polymer material 547 d making up the side portions 546 b , 546 c and a portion of the intermediate portion 546 d , 546 e on each side of the central portion 546 a of the first embodiment of the hinge body 545 a .
- the first embodiment of the hinge body 545 a will take more than one form depending on the format of the adhesive material attached to the hinge body for the purpose of sealing and sealing the hinge body 545 a to the underside of the respective rigid panels 536 on either side of the respective hinge 544 a , 544 b , 544 c .
- hinge body 545 a is secured to the underside of the respective rigid panels 546 by an adhesive material 570 a described elsewhere herein.
- hinge body 545 a is secured to the underside of the rigid panels 536 a , 536 b , respectively, by an adhesive member 571 a described elsewhere herein.
- the hinge body 545 a shown in FIG. 5 C the hinge body 545 a is secured to the underside of the respective rigid panels 536 a , 536 b with a three-part adhesive member having first, second, and third layers 572 a , 572 b , 572 c , as further described elsewhere herein.
- the first embodiment is also shown in FIGS. 17 A- 17 D in the first adhesive format employing the adhesive material 570 a.
- FIG. 17 E A further embodiment of the hinge body 545 a ′ having similar adhesive 570 a for sealing and securing the hinge body 545 a ′ to the underside of rigid panels 536 but having only a single durometer polymer design is shown in FIG. 17 E .
- This single-durometer embodiment of the hinge body 545 a ′ is also shown in FIG. 18 B , but with a different adhesive 571 format.
- a further embodiment of the hinge body 545 a ′′ is shown in FIG. 18 C and is generally the same as the single-durometer hinge body 545 a ′ shown in FIG.
- hinge body 545 a ′′ does not include a concave upper surface like hinge body 545 a ′, but has instead a flat central portion 546 ′′ in which water will not pool or run off along the length of the hinge body toward the sidewalls of the pickup truck 2 .
- 18 D- 18 F is also a single-durometer hinge body made of a flexible polymer material 547 c and it does not need an adhesive member to secure it to the underside of the rigid panels, because the close proximity of the rigid panel 536 and the support bow 550 , which has ha hinge support flange 586 having a flange lip 587 , which cooperate to form a partial enclosure 592 , described elsewhere herein, which will hold the hinge body 545 a ′′′ in place on each side of the hinge body 545 a ′′′ as shown in FIGS. 17 G, 17 H, and 18 D- 18 F .
- the flexible hinge body 545 a ′′′ preferably includes a single polymer material 547 a , and provides an effective barrier against influx of moisture, precipitation or debris into the cargo box 5 between the adjacent rigid panels 536 when the folding cover assembly 530 is unfolded and in place covering the cargo box 5 .
- the hinge body polymer material 547 a preferably includes an elastomeric polymer material 547 b and more preferably includes a thermoplastic polymer.
- the elastomeric polymer material 547 b is preferably extruded to form an elongated structure having the desired hinge body profile 545 c .
- Examples of the preferable elastomeric polymer material 547 b include Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer and Sarlink® TPV 5765B thermoplastic vulcanizate, both available from Teknor Apex Company, Pawtucket, R.I.
- Each flexible hinge body 545 a preferably includes the two side portions 546 b and 546 c , and the central portion 546 a located between the two side portions 546 b and 546 c ; each flexible hinge body 545 a preferably includes the two intermediate portions 546 d and 546 e , each one of the intermediate portions 546 d and 546 e located between the central portion 546 a and one of the two respective side portions 546 b and 546 c .
- the central portion 546 a , side portions 546 b and 546 c , and intermediate portions 546 d and 546 e of the flexible hinge body 545 a preferably extend along the length of the flexible hinge body 545 a , and the hinge thickness 545 d of the central, side, and intermediate portions 546 a - 546 e together at least partially define the hinge body profile 545 c .
- Each of the two side portions 546 b and 546 c is preferably secured to a respective adjacent rigid panel 536 .
- one of the adjacent rigid panels 536 is lifted up and folded towards the other of the adjacent rigid panels 536 , and the central portion 546 a bends to function as a hinge as further described herein.
- the flexible hinge body 545 a includes more than one polymeric material such as those described herein; for example, the flexible hinge body 545 a may include a softer or lower-durometer elastomeric polymer material 547 c and a harder or higher-durometer elastomeric polymer material 547 d .
- the central portion 546 a preferably includes the softer elastomeric polymer material 547 c
- the side portions 546 b and 546 c which are secured to the rigid panels 536 as stated, preferably include the harder elastomeric polymer material 547 d .
- a transition or mixing of the materials preferably occurs in the intermediate portions 546 d and 546 e .
- This arrangement preferably provides a structure with the central portion 546 a being more flexible in bending than the intermediate portions 546 d and 546 e and the side portions 546 b and 546 c , so that bending of the flexible hinge body 545 a preferentially occurs in the central portion 546 a , although some flexing and bending can occur in other portions of the flexible hinge 544 in addition to the central portion.
- FIG. 5 C shows the hinge illustrated in FIG. 5 B somewhat bent.
- the intermediate portions 546 d and 546 e have a transition between polymeric materials schematically indicated by a partially diagonal line in the drawings.
- the transition between materials may be gradual with a mixing of the polymeric materials in the intermediate portions, which will generally occur during either a molding process or an extrusion process, either of which could be used to manufacture a dual-durometer hinge body, so, for that reason, the line is not intended to define a precise sudden transition, but rather just generally indicate that the respective intermediate portion includes a transition between the different polymeric materials that have different durometers.
- the transition can be more sudden or more gradual.
- the transition between polymeric materials will generally be located in the respective intermediate portions 546 d and 546 e as indicated by the schematic transition line shown in these portions.
- the central portion 546 a includes the softer elastomeric polymer material 547 c , one example of which is Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer, and the side portions 546 b and 546 c include the harder or higher-durometer elastomeric polymer material 547 d , one example of which is Sarlink® TPV 5765B thermoplastic vulcanizate. These materials can be extruded together to form the disclosed structure, with a mixing of these materials occurring in the intermediate portions 546 d and 546 e .
- the thickness 545 d of the various portions of the flexible hinge body 545 a can also affect the bending properties, but the variation of polymeric materials as just described can be useful in facilitating bending of the hinge 544 in the central portion 546 a , which in use is located between the adjacent panels 536 , and in facilitating securement of the side portions 546 b and 546 c to the adjacent panels 536 .
- the flexible hinge body 545 a can include a structure fabricated by molding or other additive or subtractive manufacturing process.
- the flexible hinge body 545 a may have additional material added, such as reinforcing fibers or filaments (not shown) adhered to or incorporated into the flexible hinge body 545 a , including cloth-inserted, cloth-reinforced, fiberglass-reinforced, and fiber-reinforced polymer materials.
- the hinge body polymer material 547 a can include a vinyl material, natural or synthetic rubber or other flexible polymeric material, EPDM rubber, neoprene rubber, nitrile rubber, latex, silicone rubber, polyurethane material, or other polymer materials known in the art, or combinations of materials.
- the flexible hinge body 545 a preferably includes a flexible material that can withstand deformation without failure due to cracking or breakage to allow bending of the hinge 544 to fold up the folding cover assembly 530 , and that is moisture-resistant to avoid leakage into the cargo box 5 .
- adhesive 570 a is preferably located between each side portion 546 b and the respective rigid panel 536 as illustrated in FIG. 5 A to protect against passage of debris or precipitation into the cargo box 5 ; the adhesive 570 a can also aid in securement of the flexible hinge 544 to the respective rigid panel 536 .
- the adhesive 570 a can include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between the rigid panel 536 and the respective flexible hinge 544 or to secure the flexible hinge 544 to the respective rigid panel 536 .
- the adhesive 570 a includes a double-sided adhesive tape 571 a , which preferably includes an acrylic foam material 572 a , with adhesive layer 572 b arranged on one side of the acrylic foam material 572 a , and adhesive layer 572 c arranged on the other side of the acrylic foam material 572 a , for example.
- the double-sided adhesive tape 571 a can be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”)
- the adhesive layer 572 b includes heat-activated adhesive
- an adhesive layer 572 c includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer 572 c .
- the adhesive layer 572 b (in this example, heat-activated adhesive) is aligned with the flexible hinge body 545 a while the heat-activated adhesive is activated to adhere the double-sided adhesive tape 571 a to the flexible hinge body 545 a ; the flexible hinge body 545 a together with the attached double-sided adhesive tape 571 a is subsequently aligned with the rigid panel 536 and the release strip is removed.
- the adhesive layer 572 c is aligned with the panel 536
- the flexible hinge body 545 a is attached to the rigid panel 536 by activating the adhesive layer 572 c (in this example, pressure-sensitive adhesive).
- the adjacent rigid panel 536 is similarly attached to the flexible hinge body 545 a with double-sided adhesive tape 571 a forming the structure of hinge 544 illustrated in FIG. 5 B .
- the flexible hinge body 545 a allows the hinge 544 to take a flat or open configuration as illustrated in FIGS. 5 A and 5 B , or to flex or bend as illustrated in FIGS. 5 C, 7 C , and other figures herein, providing a flexible hinge 544 that allows the folding cover assembly 530 to fold as illustrated throughout the Figures and described herein, with rigid panels 536 folding up and rotating towards other rigid panels 536 as shown.
- the flexible hinge body 545 a is adhered to the respective bottom or underside 538 of the rigid panels 536 (specifically, the underside 538 a - 538 d off respective adjacent panels of 536 a - 536 d as described herein) of the folding cover assembly 530 as shown.
- the hinges 544 are securely attached to the respective rigid panels 536 and are sealed to prevent water or debris from entering the cargo box through the folding cover assembly 530 at the hinges 544 , and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box 5 would be exposed.
- the support bows 550 are also schematically illustrated in FIGS. 5 A- 5 C .
- the support bows preferably include a bow main portion 584 including a generally C-shaped channels with a bow upper portion 585 configured for attachment to the bottom surface 538 of the respective panel 536 and oriented with a channel opening 566 c at the bottom.
- the support bows 550 which are located at the flexible hinges 544 preferably include the hinge support flange 586 , 586 a , 586 b ; the support bows which are located at the flexible hinges 544 preferably also include the flange lip 587 , 587 a , 587 b.
- the support bows 550 are secured to the respective panel 536 .
- the support bows 550 are preferably located at the bottom surface 538 of the respective panel 536 , and near the front edge 541 b or rear edge 541 c of the respective panel 536 .
- the support bows 550 are preferably secured to the bottom surface 538 of the respective panel 536 by an adhesive 570 b , which may include a layer or coating of adhesive or a double-sided adhesive tape 571 b , for example.
- an adhesive 570 b which may include a layer or coating of adhesive or a double-sided adhesive tape 571 b , for example.
- a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination can be used to attach the support bows 550 , to the respective panels 536 .
- the double-sided adhesive tape 571 b preferably includes an acrylic foam material 572 d with adhesive layer 572 e arranged on one side of the acrylic foam material 572 d and adhesive layer 572 f arranged on the other side of the acrylic foam material 572 d , for example.
- the adhesive 570 b includes a double-sided adhesive tape 571 b such as 3M CV62F from 3M, St. Paul, Minn.
- the double-sided adhesive tape 571 b is an acrylic foam tape having an adhesive layer 572 e which includes pressure-sensitive adhesive and having an adhesive layer 572 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 572 f .
- the adhesive layer 572 e in this example, pressure-sensitive adhesive
- the adhesive layer 572 e is aligned with and adhered to the upper surface 566 d of the support bow 550 to adhere the double-sided adhesive tape 571 b to the support bow 550 ; the support bow 550 together with the attached double-sided adhesive tape 571 b is subsequently aligned with the panel 536 and the release strip is removed.
- the adhesive layer 572 f is then aligned with the panel 536 and the support bow 550 is attached to the respective panel 536 by activating the adhesive layer 572 f (in this example, pressure-sensitive adhesive).
- the adhesive layer 572 f in this example, pressure-sensitive adhesive
- any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material 572 a , 572 d is also preferable but not always required.
- a single layer of adhesive could be used, similar to the arrangement schematically illustrated in FIG. 5 A .
- Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J.
- the sidebars or handles 559 are preferably also attached to the bottom surface or underside 538 of the respective panels 536 , preferably in a similar manner as that just described for the support bow 550 .
- adhesive 570 b can be applied at selected portions of the length of the support bow 550 or the sidebar 559
- adhesive 570 b is preferably applied along substantially the entire length of the support bow 550 and the sidebar 559 , to enhance stability and to minimize unwanted vibrations.
- the sidebars 559 and support bows 550 can be attached to the panels 536 with adhesives such as glue, or with fasteners, or spot welds.
- the folding cover assembly 530 folds in stages or steps; a preferred embodiment is schematically illustrated in FIG. 5 D .
- the hinge 544 a flexes to allow the rear panel 536 a to fold up, passing through 90 degrees (configuration 2 ) towards the middle panel 536 b , and fold over onto the middle panel 536 b (configuration 3 ).
- the hinge 544 b flexes to allow the middle panel 536 b (together with the rear panel 536 a which is folded onto the middle panel 536 b ) to fold up, passing through 90 degrees (configuration 4 ) towards the spacer panel 536 d , passing through a point at which standoffs 558 contact the front panel (configuration 5 ).
- FIG. 5 D is a schematic overview of the general folding of the folding cover assembly 530 ; the various configurations are further illustrated and described elsewhere herein in greater detail.
- FIG. 5 E An alternate configuration of an alternate folding cover assembly 530 ′ folded up is schematically illustrated in FIG. 5 E .
- the front panel 536 c ′ is noticeably longer than panels 536 a and 536 b .
- the spacer panel 536 d is oriented approximately vertically when the folding cover assembly 530 is folded up, and the front panel 536 c simply extends farther frontward than the middle panel 536 b and the rear panel 536 a .
- the spacer panel 536 d is correspondingly longer to accommodate the lengths of the panels 536 a , 536 b , and 536 c ′ as illustrated.
- the spacer panel 536 d is noticeably non-vertical when the folding cover assembly 530 ′ is folded up.
- the alternate folding cover assembly 530 ′ also preferably includes corresponding flexible hinges 544 a , 544 b , 544 c and standoffs 558 .
- FIG. 5 F Another alternate configuration of an alternate folding cover assembly 530 ′′ folded up is schematically illustrated in FIG. 5 F , similar to the illustration of FIG. 5 E .
- the front panel 536 c ′′ is noticeably shorter than panels 536 a and 536 b .
- the spacer panel 536 d is oriented approximately vertically when the folding cover assembly 530 is folded up, and the middle panel 536 b and the rear panel 536 a simply extend farther frontward than the front panel 536 c .
- the spacer panel 536 d is correspondingly longer to accommodate the lengths of the panels 536 a , 536 b , and 536 c ′′ as illustrated.
- the alternate folding cover assembly 530 ′′ also preferably includes corresponding flexible hinges 544 a , 544 b , 544 c and standoffs 558 .
- the spacer panel 536 d can be oriented preferably from about zero to about 60 degrees from a vertical orientation; the orientation is determined by the various lengths of the panels 536 and a standoff distance 561 a (see FIG. 14 C ).
- the top surface 537 d of the spacer panel 536 d can stand generally at an angle of from about 30 to about 150 degrees to the top surface 537 c of the front panel 536 c , preferably from about 40 to about 140 degrees to the top surface 537 c of the front panel 536 c ; more preferably from about 50 to about 130 degrees to the top surface 537 c of the front panel 536 c ; even more preferably from about 60 to about 120 degrees to the top surface 537 c of the front panel 536 c , and even more preferably from about 80 to about 100 degrees to the top surface 537 c of the front panel 536 c , generally depending upon the length of the front panel 536 c , which can be varied in various embodiments of the cover assembly.
- the top surface 537 d of the spacer panel 536 d will generally reside at an angle of about 90 degrees to the top surface 537 c of the front panel 536 c.
- the length 539 a of the rear panel 536 a is preferably somewhat smaller than the length 539 b of the middle panel 536 b so that the rear panel 536 a does not interfere with the hinges 544 b , 544 c , support bow 550 e , or other nearby structures when the folding cover assembly 530 is folded up or unfolded. If the length 539 a of the rear panel 536 a is too much smaller than the length 539 b of the middle panel 536 b , the standoffs 558 attached to the support bow 550 a will be farther removed from the respective edges of the front panel 536 c and the middle panel 536 b and may not provide the desired support in the folded up configuration.
- the length 539 a of the rear panel 536 a is from about 0.25 inch to about 8 inches smaller than the length 539 b of the middle panel 536 b . Still more preferably, the length 539 a of the rear panel 536 a is from about 0.5 inch to about 2 inches smaller than the length 539 b of the middle panel 536 b . Even more preferably, the length 539 a of the rear panel 536 a is about 0.75 inch smaller than the length 539 b of the middle panel 536 b.
- the length 539 d of the spacer panel 536 d is large enough to accommodate the hinges 544 b and 544 c without interference with the support bow 550 e , but is preferably not significantly larger than required to accommodate the hinges 544 b , 544 c and support bow 550 e so that the stored profile of the folding cover assembly 530 is minimized, and the folded profile when the folding cover assembly 530 is folded up but remains attached to the side rails 520 a , 520 b as illustrated in FIG. 10 D is minimized, which is believed to reduce any tendency for the folding cover assembly 530 to catch wind when the folding cover assembly 530 is folded up but remains attached to the side rails 520 a , 520 b and when the truck 2 is in motion.
- the length 539 d of the spacer panel 536 d is no greater than about one-third the lengths 539 a , 539 b , 539 c of the other respective panels 536 a , 536 b , 536 c.
- the length 539 b of the middle panel 536 b is somewhat smaller than the length 539 c of the front panel 536 c so that the driver or operator 8 can easily grasp the storage straps 543 a and strap brackets 543 b , when the folding cover assembly 530 is in the folded up configuration illustrated in FIG. 10 A , to hook the strap brackets 543 b in the bracket slots 543 c at the front of the front panel 536 c as described below and illustrated in FIG. 10 A- 10 D .
- the length 539 c of the front panel 536 c is longer than the length 539 b of the middle panel 536 b , the folded up configuration of the folding cover assembly 530 , as illustrated in FIG.
- the length 539 b of the middle panel 536 b is from about 0.25 inch to about 6 inches smaller than the length 539 c of the front panel 536 c . Still more preferably, the length 539 b of the middle panel 536 b is from about 1 inch to about 3 inches smaller than the length 539 c of the front panel 536 c . Even more preferably, the length 539 b of the middle panel 536 b is about 1.733 inches smaller than the length 539 c of the front panel 536 c.
- the rear end of the rear panel 536 a can be lifted up from both side rails 520 a and 520 b , bending the hinge 544 a as illustrated in FIGS. 6 A and 6 B .
- hooks 562 at the ends of the support bow 550 at the front of the rear panel 536 a disengage from the respective catches 564 ; specifically, hook 562 a disengages from catch 564 a attached to side rail 520 a , and hook 562 b disengages from catch 564 b attached to side rail 520 b .
- the structure and function of the hooks 562 and catches 564 are described in further detail elsewhere herein (see, for example, FIG. 19 A ).
- the rear panel 536 a is rotated further, onto the middle panel 536 b as illustrated in FIGS. 7 A and 7 B .
- the middle panel 536 b can be lifted from the side rails 520 a and 520 b , with the middle panel 536 b (together with the rear panel 536 a which is folded onto the middle panel 536 b ) pivoting upwards and frontwards, bending the hinge 544 b .
- FIG. 7 A shows the hinge 544 a folded in the configuration of FIGS. 7 A and 7 B .
- the folding cover assembly 530 includes standoffs 558 , located on the underside 538 a of the rear panel 536 c .
- the standoffs 558 can be attached to the bottom side of the rear panel 536 a or attached to other structures such as support bows 550 or handles 559 ; in the example illustrated in FIGS.
- standoffs 558 there are four standoffs 558 , two of which are attached to each of two sidebars or handles 559 on the underside 538 a of the rear panel 536 c .
- the standoffs 558 are preferably located so that two are proximate the front edge 541 b of the rear panel 536 a , and two are proximate the rear edge 541 c of the rear panel 536 a .
- the standoffs 558 , and a preferred attachment of the standoffs 558 to the handles 559 are described further below, including with reference to FIGS. 14 A- 14 C .
- the standoffs 558 proximate the rear edge 541 c of the rear panel 536 a contact the top surface 537 c of the front panel 36 c as shown in FIG. 8 C .
- the standoffs 558 help to maintain a spaced relationship between the rear panel 536 a and the front panel 536 c .
- the hinge 544 c bends and the spacer panel 536 d lifts off the side rails 520 a and 520 b as illustrated in FIG. 8 D .
- the middle panel 536 b With continued rotating of the middle panel 536 b frontwards, together with the rear panel 536 a and the spacer panel 536 d , and pivoting and sliding of the standoffs 558 , the middle panel 536 b , the rear panel 536 a , and the spacer panel 536 d rotate progressively farther frontwards towards the front panel 536 c , as illustrated in FIGS. 8 E , until the standoffs 558 all contact the front panel 536 c ( FIG. 9 A ).
- the hinges 544 b and 544 c flex as the middle panel 536 b , the rear panel 536 a , and the spacer panel 536 d rotate towards the front panel 536 c as schematically illustrated in FIGS. 8 F and 10 E .
- the hinges 544 b and 544 c can flex to pass through various increasing or decreasing angles. Most commonly, however, the angles will vary in the following manner. Referring to FIGS.
- angle A between the middle panel 536 b and the spacer panel 536 d (which is about 180 degrees before beginning the folding up of the middle panel 536 b onto the front panel 536 c , as in the configuration illustrated in FIG. 7 A ) initially decreases to angle A 1 which is about 90 degrees as shown in FIG. 8 A , then decreases past 90 degrees to angle A 2 at which point the standoffs 558 contact the top surface 537 c of the front panel 536 c as shown in FIG. 8 C ; angle A 2 may be about 35 degrees, but may be somewhat larger or smaller than about 35 degrees depending on the standoff distance 561 a ( FIG.
- Angle B between the spacer panel 536 d and the front panel 536 c (which is about 180 degrees before beginning the folding up of the folding cover assembly 530 , as in the configuration illustrated in FIG. 7 A ) is shown as angle B 1 in the configuration of FIG. 8 A as about 180 degrees, and is shown as angle B 2 in the configuration of FIG.
- Angle C between the rear panel 536 b and the front panel 536 c (which is about 180 degrees before beginning the folding up of the folding cover assembly 530 , as in the configuration illustrated in FIG. 7 A ) initially decreases to angle C 1 which is about 90 degrees as shown in FIG. 8 A , then decreases past 90 degrees to angle C 2 at which point the standoffs 558 contact the top surface 537 c of the front panel 536 c as shown in FIG. 8 C .
- the angle A may remain about the same or may increase again as the angle B begins to decrease and the angle C continues to decrease, as shown as angles A 3 , B 3 , and C 3 in FIG. 8 D .
- the angles A and B continue to approach about 90 degrees as the angle C continues to approach zero degrees as shown as angles A 4 , B 4 , and C 4 in FIG. 8 E .
- angles A and B are preferably about 90 degrees and the angle C is preferably about zero degrees, as shown as angles A 5 , B 5 and C 5 in FIG. 10 D , with the rear panel 536 a , the middle panel 536 b , and the front panel 536 c being approximately parallel to each other, and the spacer panel 536 d approximately vertical, oriented at about 90 degrees with respect to the panels 536 a , 536 b , and 536 d.
- the angle C between the rear panel 536 a and the front panel 536 c decreases towards about zero degrees, passing through the configurations depicted in FIGS. 8 C- 8 E .
- the folding cover assembly 530 is folded up, but is still attached to the side rails 520 a and 520 b , with the latches 552 c and 552 d (proximate the ends of the support bow 550 f ) engaged with the side rail lip 524 of the side rails 520 a and 520 b , respectively, and the hooks 562 e and 652 f proximate ends of the support bow 550 g engaged with the catches 564 e and 564 f , respectively, as illustrated in FIGS. 10 C- 11 A .
- the containment bracket or anchor socket 525 a is affixed to the side rail 520 a (see for example FIGS. 2 E and 9 B ), and a mirror-image anchor socket 525 b is affixed to side rail 520 b (see for example FIG. 11 A ).
- the anchor sockets or containment brackets 525 a and 525 b keep the engaging portion 553 b of the latches 552 proximate each end of the support bow 550 g in a desired location along the side rail lip 524 of the side rails 520 a and 520 b and thereby aid in positioning the folding cover assembly 530 in a desired alignment with respect to the cargo box 5 when the engaging portion 553 b of the latches 552 at each end of the support bow 550 g are engaged with the side rail lip 524 of the side rails 520 a and 520 b.
- bundling means such as bungee cords or storage straps 543 a can be utilized to fix the folding cover assembly 530 in the folded configuration; other straps, buckles, or hooks can be utilized as bundling means.
- FIGS. 10 A- 10 D show a preferred embodiment, in which two elastic storage straps 543 a are provided, one towards either side of the middle panel 536 b , for securing the folding cover assembly 530 in a folded configuration.
- strap brackets 543 b are provided for each storage strap 543 a , for hooking the storage straps 543 a to the front panel 536 c ;
- the strap brackets 543 b are preferably formed of a strong polymer such as a polyamide, although other materials, including composites and metals, can be used. More preferably, the strap brackets 543 b are formed of nylon.
- bracket slots 543 c are provided in the front panel 536 c , and accommodate the strap brackets 543 b .
- the strap brackets 543 b are attached to or captured on the storage straps 543 a , and the strap brackets 543 b hook to the bracket slots 543 c in the front panel 536 c to secure the folding cover assembly 530 in the folded configuration when desired.
- a storage strap 543 a is hooked to the front panel 536 c with a strap bracket 543 b . Also illustrated on FIG.
- FIG. 10 B are support bows including support bows 550 b , 550 c , 550 d , and 550 g , swing latches 562 b , 562 d , and 562 f , standoff 558 , protective pad 558 a , and protective film 574 .
- FIG. 10 C is a front view which illustrates a storage strap 543 a near each side of the middle panel 536 b which is hooked to the front panel 536 c with corresponding strap brackets 543 b to secure the folded folding cover assembly 530 in a folded configuration as shown.
- FIG. 10 D shows a side view of this folded configuration of the folding cover assembly 530 , with the rear panel 536 a secured to the front panel 536 c .
- the folding cover assembly 530 can be left in this folded configuration, as illustrated in FIG. 10 D , covering only the front portion of the cargo box 5 .
- the protective film(s) 574 is preferably located on the top surface 537 c of the front panel 536 c so that the protective film 574 is aligned with the respective standoff 558 as illustrated in FIGS. 9 A, 10 , and 10 B , which illustrate the folding tonneau cover assembly 530 folded up.
- the protective film 574 is located as shown between the standoff 558 and the top surface 537 c of the front panel 536 c , damage to the top surface 537 c by contact and abrasion by the protective pad 558 a is minimized.
- the folding tonneau cover assembly 530 may be in the folded up configuration such as illustrated in FIG. 10 B , with the strap bracket 543 b of each storage strap 543 a engaged with the bracket slot 543 c as illustrated.
- the folding cover assembly 530 folded up and bundled and left secured to the side rails 520 a and 520 b in the configuration of FIGS. 10 B- 10 D is illustrated in a rear perspective view, viewed from slightly below and to the driver's side of the folding tonneau cover apparatus in FIG. 11 A .
- the cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b ; the clip cord guides 555 a and retainer cord guides 555 b are further illustrated in FIG. 11 B .
- the truck can be driven with the folding cover assembly 530 in this folded up configuration if desired.
- the folding cover assembly 530 can be removed as follows. As illustrated in FIG. 11 A the release cord 554 b is accessible and can easily be grasped by a driver or other operator 8 . Pulling on the release cord 554 b will retract the latches 552 at the ends of the support bow 550 f against the force of the biasing members or springs 556 , similar to the way in which pulling on the release cord 554 a retracts the latches 552 at the ends of the support bow 550 a as illustrated in FIG. 4 B .
- the release cord 554 b will be pulled by a driver or other operator 8 ; the operator 8 preferably has entered the cargo box 5 via the tailgate 6 d to grasp the release cord 554 b .
- the engaging portions 553 b of the latches 552 at the ends of support bow 550 f are retracted away from the lips side rail lips 524 of the side rails 520 a and 520 b , releasing the latches 552 from the side rails 520 a and 520 b , and allowing the rear portion of the front panel 536 c to be lifted up from the side rails 20 a and 20 b and rotated to disengage the hooks 562 e and 562 f from the catches 564 e and 564 f , respectively.
- the folded folding cover assembly 530 is free from the side rails 520 a and 520 b of the support frame assembly 518 and can be lifted up and off the cargo box 5 as illustrated in FIG. 12 ; the folding cover assembly 530 can be moved away from the pickup truck 2 , or stowed in the cargo box 5 or elsewhere as desired. In this case, the top opening 6 f of the cargo box 5 is not partially covered by the folded up folding cover assembly 530 .
- the various steps illustrated can be done in the reverse order, as described in further detail below in reference to FIG. 19 C .
- To latch the various latches 552 it is not necessary to manually retract any of the release cords 554 , since the latch slide 553 has an inclined bottom surface 553 a .
- the inclined bottom surface 553 a of the latch slide 553 will retract the engaging portion 553 b to allow the engaging portion 553 b to move past the side rail lip 524 , whereupon the spring 556 will move the engaging portion 553 b into the secured configuration, such as illustrated in FIG. 3 B and elsewhere herein.
- the cord guides 555 are schematically illustrated.
- the cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b .
- Each clip cord guide 555 a is preferably attached to a support bow 550 as illustrated in FIGS. 13 A- 13 C .
- the clip cord guide 555 a preferably has a securement feature or securement portion 560 a which is configured for attachment to the support bow 550 .
- the securement feature 650 a is preferably oblong and is narrow enough to fit into the channel opening 566 c , and when aligned with the open bottom of the bow bottom portion 566 b as illustrated in FIG.
- the securement feature 650 a can be inserted into the support bow 550 as shown in FIG. 13 B .
- the clip cord guide 555 a is then rotated as indicated by the arrow on FIG. 13 B so that the securement feature 650 a secures the clip cord guide 555 a to the support bow 550 as shown in FIG. 13 C .
- Each retainer cord guide 555 b is preferably inserted into the open end of the support bow 550 and slid along the support bow 550 to a desired location.
- the release cord 554 passes between the retainer cord guide 555 b and the support bow 550 as schematically illustrated in FIG. 13 D so that the retainer cord guide 555 b retains the release cord 554 .
- clip cord guide(s) 555 a and retainer cord guide(s) 555 b keep the respective release cord positioned in alignment with the latches 552 and adjacent to or within the respective support bow 550 .
- some elements are not shown, such as the adhesive 570 b (which may include adhesive tape 571 b ), hinge 544 , hinge support flange 586 , and so forth, in order to highlight the particular features being described.
- the elements shown in the schematic illustrations of FIGS. 13 A- 13 D are not necessarily drawn to scale.
- the standoff 558 preferably has a securement portion 560 b which is configured for attachment to the sidebar or handle 559 .
- the securement portion 560 b preferably includes two longitudinal grooves 558 b and 558 c which can engage the handle 559 .
- the standoff 558 preferably includes an elongated projection 558 d which can be grasped to snap the standoff 558 onto the handle 559 or to remove the standoff 558 from the handle 559 . Further, the elongated projection 558 d is preferably angled to aid in guiding the standoff 558 into engagement with the handle 559 .
- the longitudinal groove 558 b is hooked onto the handle 559 as illustrated in FIG. 14 B
- the elongated projection 558 d is used to aid in hooking the longitudinal groove 558 c onto the handle 559 to secure the standoff 558 on the handle 559 as illustrated in FIG. 14 C
- the dimensions of the standoff 558 and position of the standoff 558 including the standoff distance 561 a and the setback distance 561 b ( FIG. 10 D ) when secured to the handle 559 together determine the angle C 2 ( FIG. 8 C ) at which the standoff 558 contacts the front panel 536 c when the folding cover assembly 530 is being folded up.
- a protective pad or insert or rubber foot 558 a is attached to the end of the standoff 558 as shown; the protective pad 558 a preferably secures to the standoff 558 by adhesive such as those described herein or other adhesive known in the art.
- the protective pad 558 a serves to reduce impact or abrasion damage to the front panel 536 c when the folding cover assembly 530 is folded up onto the front panel 536 c.
- the length 539 d of the spacer panel 536 d is substantially smaller than the lengths 539 a , 539 b , 539 c of the other panels 536 a , 536 b , 536 c ( FIG. 2 A ).
- the dimensions of the standoff 558 are chosen to accommodate the length 539 d of the spacer panel 536 d , so that the front panel 536 a and the rear panel 536 c are preferably parallel and separated from one another in the folded configuration such as is illustrated in FIG. 10 D .
- the larger lengths 539 a , 539 b , 539 c of panels 536 a , 536 b , 536 c provide for efficient coverage of the cargo box 5
- the smaller length 539 d of the spacer panel 536 d provides for folding up of the folding cover assembly 530 to a convenient folded size, while providing space for the various hinges 544 , support bows 550 , and other components within the folded-up folding cover assembly 530 .
- the standoff 558 the rear end of each of the handles 559 attached to the bottom surface 538 a of the rear panel 536 a contacts the front panel 536 c and provides a pivot point and sliding support to aid in orienting the panels 536 in the folded configuration as shown.
- the standoff 558 is long enough to ensure contact between the protective pad 558 a and the top surface 537 c of the panel 536 c in order to minimize movement and stress on the hinges 544 b and 544 c and to minimize any damage due to abrasion between the protective pad 558 a and the top surface 537 c of the panel 536 c .
- the standoff 558 is short enough to avoid undue stress on the panel 536 c and the hinges 544 b and 544 c when the folding cover assembly 530 is folded up as illustrated in FIGS. 10 A- 10 D .
- the perimeter seal 534 provides a seal against the entry of water, dust, or other debris into the cargo box 5 around the perimeter of the folding cover assembly 530 .
- the perimeter seal 534 can also adapt to irregularities in the fit between the folding cover assembly 530 and the sidewalls 6 a , 6 b , front wall 6 c , and tailgate 6 d of the cargo box 5 .
- the perimeter seal 534 is preferably attached to the panels 536 with adhesive such as adhesive 570 a , 570 b described above, although other attachment mechanisms can be used to secure the perimeter seal 534 to the underside 538 of the respective panel 536 , such as those described herein for attachment of the flexible hinge 544 or the support bows 550 or the handle 559 to the panels 536 .
- FIG. 15 A schematically illustrates one example perimeter seal 534 a having D-shaped cross section as shown.
- adhesive 535 is used to secure the perimeter seal 534 to the panels 536 ; although other types of adhesive, such as pressure-activated, heat-activated, UV-activated, chemical-reaction-cure, or other adhesives that are known in the art, can be used, preferably adhesive 535 is an adhesive such as the previously described adhesives 570 a , 570 b , 571 a , 571 b .
- FIG. 15 B schematically illustrates another example perimeter seal 534 b having a perimeter seal lip 534 d ; perimeter seal lip 534 d can aid in alignment of the perimeter seal 534 at the edge of the panel 536 , and can also provide some protection when manipulating panel 536 so that injury from contact with any narrow or sharp edges of the panel 536 is avoided.
- FIG. 15 C schematically illustrates another example perimeter seal 534 c having an extended perimeter seal flange 534 e which provides similar advantages as the perimeter seal lip 534 d but also extends a short distance over the top surface of the panel 536 ; the example perimeter seal 534 c has an open cross section with an extended sealing feature 534 f .
- Different configurations of the perimeter seal 534 can be used in different portions of the folding cover assembly 530 .
- perimeter seal 534 a could be used along the front of the front panel 536 c to seal against the front wall 6 c of the cargo box 5
- perimeter seal 534 b could be used along the sides of the panels 536 to seal against the sidewalls 6 a , 6 b (or sidewall cap 6 e , if the truck 2 is so equipped)
- perimeter seal 534 c could be used along the rear of the rear panel 536 a to seal against the tailgate 6 d
- Further example perimeter seals include perimeter seal 534 g , schematically illustrated in FIG. 15 D , which has an open cross section similar to perimeter seal 534 c but without an extended lip or flange.
- FIG. 15 E illustrates an example perimeter seal 534 h which is similar to perimeter seal 534 b but also includes an extended perimeter seal flange similar to that shown in FIG. 15 C .
- FIG. 15 F shows an edge guard 534 i for attachment at an exposed edge of a panel 536 but with minimal intrusion along the top surface 537 or the bottom surface or underside 538 of the respective panel 536 (corresponding to the top surface 532 a or the bottom surface 532 b , respectively, of the folding cover assembly 530 ); edge guard 534 i can be used for protection at the rear edge of the rear panel 536 a , for example.
- Edge guard 534 i is preferably secured by an interference fit with the respective panel 536 ; alternatively, edge guard 534 i can be secured to the respective panel 536 by an adhesive such as adhesive 535 illustrated in FIGS. 15 A- 15 E, 15 G- 15 H .
- FIG. 15 G schematically illustrates a perimeter seal 534 j similar to perimeter seal 534 g of FIG. 15 D but having an extended sealing feature 534 f somewhat shorter than the perimeter seal of FIG. 15 D , as shown.
- a preferred perimeter seal 534 k is schematically illustrated in FIG. 15 H .
- the perimeter seal 534 k preferably includes extended sealing feature 534 f and a thick back portion 534 m , with the adhesive 535 located at the thick back portion 534 m for securing the perimeter seal 534 k to the respective panel(s) 536 .
- the perimeter seal 534 can be formed into a bend at the corners of the cargo box 5 , or separate segments of the perimeter seal 534 can be applied near each of the driver's side, passenger side, front side, and rear side of the folding cover apparatus 530 , preferably cut to meet at a 45 degree angle to provide an essentially continuous perimeter seal around the perimeter.
- perimeter seal 534 in a similar manner, differing configurations of perimeter seal 534 , such as various perimeter seals 534 a , 534 b , 534 c , 534 g , 534 h , 534 j , and 534 k described herein can be used along different portions of the perimeter, preferably cut to meet in close approximation and thereby providing an essentially continuous perimeter seal around the perimeter but with differing seal configurations at different portions of the perimeter.
- An edge guard such as edge guard 534 i can be used to protect against damage or injury from the edge of the panel 536 .
- the perimeter seal 534 is arranged to provide an essentially continuous seal around the perimeter of the cargo box 5 , and in addition, the rear edge of the rear panel 536 a preferably has an edge guard 534 i .
- some portions of the folding cover assembly 530 have perimeter seals 534 (which may include perimeter seals 534 a , 534 b , 534 c , 534 g , 534 h , 534 j , 534 k , for example) in addition to edge guard 534 i .
- the extended perimeter seal flange 534 e can be incorporated into the perimeter seal 534 so that a separate edge guard 534 i is not required.
- the folding cover assembly 530 described herein includes a perimeter seal such as a perimeter seal disclosed herein, such as perimeter seal 534 , 534 a , 534 b , 534 c , 534 g , 534 h , 534 j , 534 k .
- a perimeter seal such as a perimeter seal disclosed herein, such as perimeter seal 534 , 534 a , 534 b , 534 c , 534 g , 534 h , 534 j , 534 k .
- the perimeter seal is not shown for clarity of illustration.
- the folding cover assembly 530 preferably includes the perimeter seal 534 a along each of the sidewalls 6 a and 6 b , and the perimeter seal 534 k along the front wall 6 c , and the perimeter seal 534 h along the rear portion (proximate the tailgate 6 d ).
- the panels 536 preferably include sheet metal, although a rigid and tough polymer sheet can be used. In particular, lightweight and strong metal alloys, such as aluminum alloys, are preferred.
- the panels 536 are preferably relatively rigid as compared to the hinges 544 , so that when the folding cover assembly 530 is folded up as described herein, the panels 536 remain relatively flat, while the hinges 544 can flex to fold up the folding cover assembly 530 .
- the panels 536 are from about 0.020 inches to about 0.200 inches thick.
- the panel material is 5052-T34 rolled aluminum alloy from Aleris Inc., Cleveland, Ohio, which has a thickness of about 0.063 inches thick and is coated on the top with a Krystal KoteTM polyester paint system coating from Valspar Sourcing, Inc., Minneapolis, Minn. and on the bottom with a clear epoxy coating while it is in the factory.
- the rolled aluminum alloy is manufactured into a coil of rolled aluminum. Once cooled, the coil is unrolled and separately coated on the top and the bottom surfaces of the aluminum material, heat treated and recoiled for delivery to a material handler or to the buyer.
- the coated panel material is then unrolled and panels are cut using a laser cutting machine or such other equipment that allows the panels to be effectively cut to desired size and shape specifications.
- the thickness of the respective panels is minimized to limit the weight of the respective panels and the cost of the materials, but it the panels are too thin they will be subject to deformation between supporting structures.
- the panel material will preferably have a thickness of from about 0.020 inches to about 0.200 inches, more preferably from about 0.030 inches to about 0.126 inches, still more preferably from about 0.040 inches to about 0.100 inches, even more preferably from about 0.050 inches to about 0.080 inches, and most preferably about 0.063 inches.
- Other protective coatings can be used, such as urethane coatings, which may include UV protection. Protective coatings may be obtained, for example, from BASF (Wyandotte, Mich.) and Glasteel (Moscow, Tenn.). One preferred protective coating is BASF Elastocoat R85A92 WHT.
- Other rigid panels such as fiber reinforced plastic panels, such as can be obtained from Polser FRP Panels, Inc. (Izmir, Turkey).
- This most preferred thickness was selected for a number of reasons including strength and process limitations.
- 0.063 inches is the thickest size that is believed to be presently available from manufacturers of the product. Since this was the thickest material that could be obtained with the preferred coating, the rigid alloy 5052-T34 with the aforementioned coatings was selected from a number of other materials having a number of other sizes. The inventors have determined that using an aluminum alloy allows the cover to be both light weight and rigid. The 5052-T34 material was chosen because it allows the cover to be strong and resistant to permanent deflections under static loads, denting, bending and long term abuse.
- the thickness also creates limitations if it is too thick because the panels 536 may interfere with one another at the hinge locations when the folding tonneau cover 530 is folded up and can therefore add a lot of unwanted stress on the hinge flexible hinge body 545 a or the adhesive 570 a , 571 a where the respective hinges 544 are attached and sealed to the adjacent panels 536 . If the panel material is too thin, the panels 536 will sag and easily deform with static loads.
- panels 536 are used to make the panels 536 such as steel, aluminum, fiberglass, carbon fiber, ceramic, thermoset plastics, thermoplastics, HDPE, LDPE, ABS, PVC, Nylon, titanium alloy, magnesium alloy, copper, brass, stainless steel, rubber, fiber-reinforced or glass-containing polymeric materials and the like.
- the preferred coatings on the panels 536 are a Kyrstal KoteTM polyester paint system from Valspar, preferably a black polyester base coat with a clear texture top coat on the top surface 537 and a clear epoxy coating on the underside or bottom surface 538 of the panels 536 .
- Other coatings that could be used in alternate embodiments include acrylic paints, polyester paints, epoxy coatings, galvanized coatings, zinc plating, anodizing, other plating systems and the like.
- Alternative coatings include any combination of the above-mentioned coatings on either the top or the bottom sides of the panels 536 .
- the texture on the top surface 537 , bottom surface 538 of the respective panels 536 can be smooth, brushed, embossed, dented, sandblasted, rolled, waved and the like. Although a black top surface is preferred on the panels 536 , coating including others colors that are well known in the art may also be applied on the top surfaces 537 and the bottom surfaces 538 of the respective panels 536 in alternative embodiments. It will be appreciated that the coating on the respective surfaces are desirable both aesthetically and functionally to enable the respective surfaces to hold up over time in harsh environments.
- the support bows 550 are preferably metal channels, more preferably extruded aluminum, although a strong thermoplastic or other polymeric material that is either molded or extruded could be used.
- the support bows 550 b - 550 f have a slight bend or bow, and are curved so that they are downwardly concave or concave down as shown (deflection distance d is exaggerated in some views for clarity of illustration).
- the panels 536 When the panels 536 are attached to the bent support bows 550 b - 550 f , the panels 536 deflect and take on a corresponding slight bend or bow, except for the rear portion of the rear panel 536 a and the front portion of the front panel 536 c , which are preferably flat so that they approximate the shape of the tailgate 6 d and the front wall 6 c of the cargo box 5 .
- the support bows 550 a and 550 g are preferably straight.
- the resulting slight bow in the folding cover assembly 530 aids in shedding of water or debris from the folding cover assembly 530 .
- the support bows 550 preferably include extruded channel, as long as the upper surface 566 d of the support bow 550 has this downward curvature, the curvature will be imposed upon the panels 536 in the manner described.
- An example support bow 550 which is straight is schematically illustrated in FIG. 16 A ; the support bow 550 a at the rear of the rear panel 536 a and support bow 550 g at the front of the front panel 536 c are preferably straight.
- Support bows 550 which are curved or bent are schematically illustrated in FIGS.
- the support bows 550 b , 550 c , 550 d , 550 e , and 550 f are preferably curved.
- Such curved support bows 550 are referenced as 550 ′ in FIGS. 16 B, 16 C, and 16 E, 550 a ′ in FIG. 16 G, 550 d ′, 550 f ′ in FIG. 16 I, and 550 e ′ in FIG. 16 K , to distinguish them from the straight support bows 550 , 550 a , 550 d , 550 f , and 550 e , respectively, in FIGS.
- each respective support bow 550 ′, 550 a ′, 550 d ′, 550 f ′ is preferably curved so that the upper surface 566 d at the ends of the respective support bow 550 are a deflection distance d lower than a highest extent of the upper surface 566 d of the support bow 550 as shown (between the ends of the support bow 550 , but preferably at the center portion of the support bow 550 as shown in FIG. 16 B ).
- the deflection distance d is preferably between about zero and about 1 inch; more preferably, the deflection distance d is preferably between about 1/64th inch and about 1 ⁇ 2 inch; still more preferably, the deflection distance d is about 1 ⁇ 8 inch.
- These example approximate deflection distances are for a typical cargo box 5 of a typical pickup truck 2 ; for wider or narrower cargo boxes, the length of the respective panels 536 and the respective support bows 50 may be longer or shorter, and the deflection distance d is preferably correspondingly larger or smaller, in order to provide a similar function in aiding the run-off of water or other debris from the panels 536 .
- most common pickup truck cargo boxes are from about 3.5 feet to about 6 feet in width; the deflection distance is preferably correspondingly smaller or larger when the folding cover assembly is sized to cover a cargo box which is narrower than about 3.5 feet or wider than about 6 feet, respectively.
- a deflection distance d which is about 1/16 inch or less typically does not provide the preferred water run-off.
- a deflection distance d which is about 3/16 inch or more can create unwanted stress particularly in the panels 536 a and 536 c which preferably have one curved support bow 550 and one generally straight support bow 550 configured to approximate the shape of the tailgate 6 d and the front wall 6 c of the cargo box 5 . Therefore, we have found that for the typical truck cargo boxes 5 about 3.5 to about 6 feet in width, the preferred deflection distance is between about 1/16 inch and 3/16 inch.
- support bows 550 include optional opposed support holes 574 e in the front and rear portions of the support bow as illustrated.
- Support bow 550 e is shown in FIG. 16 J , which also illustrates bow main portion 584 , bow upper portion 585 , hinge support flange 586 , and flange lips 587 a and 587 b .
- curved support bow 550 e ′ is shown in FIG. 16 K , which also illustrates bow main portion 584 ′, bow upper portion 585 ′, hinge support flanges 586 a ′ and 586 b ′, and flange lips 587 a ′ and 587 b′.
- the support bows 550 include the bow main portion 584 including a generally C-shaped channel with the bow upper portion 585 configured for attachment to the bottom surface 538 of the respective panel 536 and oriented with the channel opening 566 c at the bottom.
- Some components of the folding tonneau cover apparatus 510 preferably slide into or are attached to the support bows 550 , including the latch slides 553 , the cord guides 555 , the standoffs 558 , spring 556 , and the spring retainers 557 a .
- the bow end caps 565 preferably slide into the ends of the support bows 550 .
- Some embodiments include support bows 550 that are straight, such as the support bows 550 that are schematically illustrated in FIGS. 16 F, 16 H, and 16 J , which include no hinge support flange 586 a , 586 b , one hinge support flange 586 a , 685 b , or two hinge support flanges 586 a , 586 b , respectively.
- Some embodiments include support bows 550 that are curved or bent, such as the support bows 550 that are schematically illustrated in FIGS.
- the folding cover assembly 530 preferably includes support bows 550 that are straight as support bows 550 a and 550 g illustrated in FIGS. 2 B, 16 A, and 16 F ; support bows 550 a and 550 g are not adjacent to a hinge 544 and therefore do not require a hinge support flange 586 a or 586 b ( FIGS. 16 A, 16 F ).
- the folding cover assembly 530 preferably includes support bows 550 that are curved or bent (concave down) and include a hinge support flange 586 a located to one side of the bow main portion 584 and extending to support the hinge side portion 546 b , 546 c as described above and further illustrated in FIGS. 16 H and 16 I .
- the folding cover assembly 530 more preferably includes support bows 550 that are bent and have a hinge support flange 586 a as support bows 550 b , 550 c , 550 d and 550 f ( FIG. 2 B ).
- the folding cover assembly 530 includes a support bow 550 that includes two hinge support flanges 586 a and 586 b , located on opposed sides of the bow main portion 584 , each hinge support flange 586 a , 586 b extending to support the hinge side portion 546 b , 546 c of hinge 544 b , 544 c , as described above and further illustrated in FIGS. 16 J and 16 K .
- the folding cover assembly 530 more preferably includes a support bow 550 that is bent and has two hinge support flanges as support bow 550 e ( FIGS. 2 B, 16 K ).
- the sidebars or handles 559 are attached to panels 536 a , 536 b , and 536 c near each side of each panel 536 .
- the sidebars 559 provide additional support along the side portions of the panels 536 .
- the sidebars 559 are preferably metal, although a strong polymer can be used. More preferably, the sidebars 559 are formed of aluminum.
- the sidebars 559 are preferably formed with recesses or other grasping features, to facilitate grasping for lifting and positioning the panels 536 during opening and closing of the folding cover assembly 530 .
- the support bows 550 and the sidebars or handles 559 are elongated, so that they can provide support across the width 540 or length 539 , respectively, of the respective panel 536 .
- FIGS. 17 A- 17 B viewed along the viewing line 17 A- 17 A in FIG. 3 A , additional details in the vicinity of the side of the spacer panel 536 d are illustrated.
- These views show hinges 544 b and 544 c , latch 552 d , and support bows 550 d , 550 e , 550 f , and the containment bracket 525 b .
- the middle panel 536 b has been raised up to begin folding this portion of the folding cover assembly 530 .
- the hinge 544 b is shown flexing, and the hook 562 d is rotated and displaced from the catch 564 d so that the spacer panel 536 d can also be lifted up.
- Some elements shown elsewhere herein are not shown in FIGS. 17 A and/or 17 B to show the hinge function more clearly.
- the hinge body 545 a is further illustrated in FIG. 17 C , which is an isolated perspective view of the hinge body 545 a and the adhesive 570 a , illustrating the hinge longitudinal axis 545 b , the hinge body profile 545 c along a representative vertical front-rear section plane 597 , the hinge body upper surface 595 , the hinge body lower surface 596 , representative hinge thickness 545 d in two locations, the central portion 546 a , the side portions 546 b , 546 c , and the intermediate portions 546 d , 546 e.
- the flexible hinge body 545 a preferably includes more than one polymeric material such as those described herein; for example, the flexible hinge body 545 a may include a softer or lower-durometer elastomeric polymer material 547 c and a harder or higher-durometer elastomeric polymer material 547 d .
- the central portion 546 a preferably includes the softer elastomeric polymer material 547 c , and the side portions 546 b and 546 c , which are secured to the rigid panels 536 as stated, preferably include the harder elastomeric polymer material 547 d .
- a transition or mixing of the materials preferably occurs in the intermediate portions 546 d and 546 e .
- This arrangement preferably provides a structure with the central portion 546 a being more flexible in bending than the intermediate portions 546 d and 546 e and the side portions 546 b and 546 c , so that bending of the flexible hinge body 545 a preferentially occurs in the central portion 546 a , although some flexing and bending can occur in other portions of the flexible hinge 544 in addition to the central portion.
- FIGS. 18 A- 18 F are schematic illustrations similar to those of FIGS. 5 A and 5 B , with similar orientation as viewed from line 5 A- 5 A on FIG. 2 A .
- FIG. 17 D A portion of the hinge body 545 a is shown in a perspective view in FIG. 17 D taken from the dashed rectangle 17 D shown in FIG. 17 C , which shows the hinge body profile 545 c of the hinge body 545 a , and also showing the central portion 546 a , the side portions 546 b and 546 c , the intermediate portions 546 d and 546 e , more flexible polymer material 547 c , stiffer polymer material 547 d , intermediate polymer material 547 e , adhesive 570 a and 570 b , hinge body upper surface 595 , and hinge body lower surface 596 .
- a portion of the hinge body 545 a ′ is shown in perspective view in FIG. 17 E which is similar to the view shown in FIG. 17 D , except that the hinge body that is shown is an alternate hinge body 545 a ′, which shows the hinge body profile 545 c ′ of the hinge body 545 a ′, and also showing the central portion 546 a ′, the side portions 546 b ′ and 546 c ′, the intermediate portions 546 d ′ and 546 e ′, hinge body polymer material 547 a ′, and double-sided adhesive tape 571 a .
- a portion of the hinge body 545 a ′′′ is shown in perspective view in FIG. 17 F which is similar to the view shown in FIG.
- hinge body that is shown is an alternate hinge body 545 ′′′, which shows the hinge body profile 545 c ′′′ of the hinge body 545 a ′′′, and also showing the central portion 546 a ′′′, the side portions 546 b ′′′ and 546 c ′′′, the intermediate portions 546 d ′′′ and 546 e ′′′, hinge body polymer material 547 a ′, and double-sided adhesive tape 571 a.
- FIG. 17 G A portion of the hinge body profile 545 c ′′′ of hinge body 545 a ′′′ is shown in FIG. 17 G , in an enlarged schematic illustration similar to that shown in FIG. 18 J , which is referenced herein below, except that the hinge body 545 a , shown in FIG. 18 J , is somewhat different from that of the hinge body 545 a ′′′ which allows the configuration of the partial enclosure 592 to engage the alternate hinge body 545 a ′′′ in a slightly different manner wherein the panel 336 does not abut against the hinge body 545 a ′′′ the same way that is shown in FIG. 18 J .
- the hinge body 545 a ′′′ is shown in a further enlargement, shown in FIG. 17 H , which is taken from the dashed circle 17 H of FIG. 17 G , which illustrates a portion of the hinge body 545 a ′′′ and the partial enclosure 592 in which the hinge body is secured and also showing the gap 590 between a first point 593 a on the lip 587 b of the support flange 586 b of the support bow 550 and a second point 593 b at the lower corner of the rigid panel 536 .
- the preferred hinge body 545 a ′′′ will be made of a single polymeric material 547 a having a single durometer, as shown in FIGS. 17 F, 17 G, 17 H, 18 D, 18 E and 18 F and no adhesive material will be required to secure the hinge body 545 a ′′′ within the partial enclosure 592 created in part by both the bottom surface 538 of the respective rigid panel 536 and a support bow 550 secured to the bottom surface 538 of the rigid panel 536 on each side of the hinge 544 so as to secure the respective side portion 546 b , 546 c and intermediate portion 546 d , 546 e at least partially within the respective partial enclosure 592 .
- various ways of incorporating adhesive materials into the folding tonneau cover assembly 540 are used to secure the respective hinge body 545 a within the respective partial enclosure 592 , but with this embodiment of the hinge body 545 a ′′′ it will be appreciated that the partial enclosure 592 is sufficient to retain the hinge body 545 a ′′′ without having a need for adhesive material to secure the hinge body 545 a ′′′ within the partial enclosure 592 .
- the hinge body 592 a ′′′ may also be made of multiple polymeric materials and be made of dual or multiple durometer material (not shown) and not require adhesive material for suitable securement in the partial enclosure 592 and adhesive material can, of course, be used to secure the alternate hinge body within the partial enclosure 592 .
- the partial enclosure 592 on each side of the hinge body 545 a ′′′ is constructed and arranged to retain one of the respective side portions 546 b , 546 c and the adjacent intermediate portions 546 d , 546 e within the partial enclosure 592 without a need for any adhesive. It will be appreciated that the lack of a need for an adhesive is especially advantageous during the assembly process and also if a need arises to remove and replace the hinge body after manufacture.
- the key to retaining the hinge body 545 a ′′′ within the partial enclosure 592 is the limited width of a gap 590 that exists between a first point 593 a on an inside surface of the lip 587 of the support flange 586 of the support bow or support member 550 that is secured to a bottom surface 538 of the proximate panel 536 and a second point 593 b at the bottom corner of the adjacent rigid panel 536 .
- This gap 590 is constructed and arranged to be large enough to accommodate a portion of the hinge body 545 a ′′′ that resides between the central portion 546 a ′′′ and the respective intermediate portion 546 d ′′′, 546 e ′′′ to fit within the gap 590 . As shown in FIG.
- the length of gap 590 which is the same as the length of the dashed line 594 , that extends from the first point 593 a on the inside surface of the lip 587 b to the second line 593 b at the lower corner of the bottom surface 538 of the rigid panel 536 .
- This dashed line 594 which has the same length as the gap 590 , is longer than the line 576 that extends from the upper surface 595 of the hinge body 545 a ′′′, proximate the second point 593 b , to the lower surface 596 of the hinge body 545 a ′′′, proximate the first point 593 a .
- Lines 577 a , 577 b , and 577 c are each parallel to line 576 and also parallel to dashed line 594 .
- lines 577 a 577 b , and 577 c are each successively longer in length than the line 594 and line 576 , because the width of the intermediate portion 546 d ′′′ and 546 e ′′′ on each side of the central portion 546 a ′′′ become progressively wider or larger as the lines grow progressively further away from the gap 590 and the upper surface 595 and the lower surface 596 diverge from one another as these respective surfaces become farther away from the gap in the immediate vicinity of the intermediate portions 546 d ′′′, 546 e ′′′, respectively.
- the edges of the gap 590 are generally unyielding because the preferred rigid panels 536 and the preferred support bows 550 are preferably made of aluminum which is generally unyielding when a polymeric material such as the polymeric material preferably used to make the hinge bodies 545 a of the present invention are drawing against the aluminum under great force. In most cases, the polymeric material will tear or deform before the aluminum material will bend significantly or break, but in any case, such levels of force are not generally expected under the anticipated conditions under which such tonneau cover assemblies are generally required to operate.
- the thickness of the respective shoulder or intermediate portion 546 d ′′′, 546 e ′′′ of the hinge body 545 a ′′′ becomes greater as the thickness is measured in lines 577 a , 577 b , and 577 c , which are each of incrementally greater length than the prior line as the distance from the central portion 546 a ′′′ of the hinge body 545 a ′′′ increases in series: 577 a to 577 b to 577 c .
- Each of these lines are incrementally greater in length than line 575 that stretches from a point on the upper surface 595 of the hinge body proximate the second point 593 b on the lower corner of the most proximate rigid panel 536 to a point on the lower surface 596 proximate the first point 593 a on the lip 587 of the support flange respective 586 .
- Each of the lines 577 a , 577 b , 577 c are parallel to line 275 and each is incrementally longer and incrementally farther away from the line 275 .
- the shoulder 546 d ′′′, 546 e ′′′ becomes wider or thicker as the shoulder becomes farther removed from the central portion 546 a ′′′ the shoulders 546 d ′′′, 546 e ′′′ and the side portions 546 b ′′′, 546 c ′′′ of the hinge body 545 a ′′′ are restricted from becoming disengaged from the partial enclosure 592 by being drawn out of the partial enclosure 592 through the gap 590 .
- the configuration is similar to that illustrated in FIG. 5 A ; the support bows 550 b and 550 c have hinge support flanges 586 a and 586 b , respectively, but lack the flange lips 587 a and 587 b which are present in the embodiment illustrated in FIG. 5 A .
- the arrangement preferably includes adhesive 570 a to secure and seal the respective side portions 546 b , 546 c to the bottom surface 537 of the respective rigid panels 536 a and 536 b.
- FIG. 18 B the configuration is similar to that illustrated in FIG. 5 A , except that an alternate hinge 544 ′ is shown, having a hinge body 545 a ′ that has a single hinge body polymer material 547 a (which preferably includes an elastomeric polymer material 547 b and more preferably includes a thermoplastic polymer as stated above) is used throughout the central portion 546 a ′ and the side portions 546 b ′ and 546 c ′ of the flexible hinge body 545 a ′.
- a single hinge body polymer material 547 a which preferably includes an elastomeric polymer material 547 b and more preferably includes a thermoplastic polymer as stated above
- bending of the flexible hinge body 545 a ′ preferentially occurs in the central portion 546 a ′ based on the hinge thickness 545 d of the central portion 546 a ′ and the side portions 546 b ′ and 546 c ′ of the flexible hinge body 545 a′.
- FIG. 18 C the configuration is similar to that illustrated in FIG. 18 B , but an alternate hinge 544 ′′ is shown, having a hinge body 545 a ′′ that has hinge body profile 545 c ′′ that is different, having a more uniformly flat profile in the central portion 546 a ′′ than in the embodiment illustrated in FIG. 18 B .
- FIG. 18 D the configuration is similar to that illustrated in FIG. 18 B , but an alternate hinge 544 ′′′ is shown, having a hinge body 545 a ′′′ but the adhesive 570 a is not used at the side portions 546 b ′′′ and 546 c ′′′ and instead the hinge thickness 545 d at the side portions 546 b ′′′ and 546 c ′′′ is such that each side portion 546 b ′′′, 546 c ′′′ preferably contacts both the respective hinge support flange 586 a , 586 b and the respective bottom surface 538 of the respective rigid panel 536 without intervening adhesive 570 a.
- FIG. 18 E shows a portion of one of the panels 536 broken away to show the underlying structure of the hinge 544 ′′′, and which shows the flexible hinge body 545 a ′′′, and the central portion 546 a ′′′, and illustrates the partial enclosure 592 in which a portion of the hinge body 545 ′′′ is secured.
- FIG. 18 F An enlarged view of the portion of the flexible hinge 544 ′′′ shown in the encircled area labeled 18 F in FIG. 18 E is illustrated in FIG. 18 F .
- a portion of the hinge body 545 a ′′′ and the central portion 546 a ′′′, and the lip 587 are shown, and the hinge body 545 a ′′′ is partially enclosed in the partial enclosure 592 .
- the lip 587 has a point 593 a closest to the panel 536 .
- the partial enclosure 592 is illustrated in FIG. 18 G in a further schematic perspective view similar to FIG. 18 E but showing the structure of the partial enclosure 592 with the hinge body 545 a shown only partially and in phantom, with the rigid panels 536 and support bows 550 shown in cooperation with one another as shown in FIG. 18 D .
- FIG. 18 H is an enlarged view providing a transverse vertical cross section of the portion of the folding tonneau cover assembly shown in FIG. 18 A , but showing the hinge body 545 a in phantom.
- FIG. 18 I is a further enlarged view similar to that shown in FIG. 18 H , except that the hinge body 545 a is shown in cross section and the rigid panels 536 and the support bows 550 are shown in phantom.
- FIG. 18 J A further enlarged view of the portion of the folding tonneau cover assembly 530 shown in the dashed circle 18 J of FIG. 18 I is illustrated in FIG. 18 J .
- Portions of the partial enclosure 592 , hinge 544 , hinge body 545 a , central portion 546 a , side portions 546 b and 546 c , intermediate portions 546 d and 546 e , hinge body profile 545 c , hinge thickness 545 d , hinge adhesive 570 a , hinge body upper surface 595 , and hinge body lower surface 596 are shown.
- Portions of the support bows 550 and rigid panels 536 are shown in phantom.
- the hinge thickness 545 d between the hinge upper surface 595 and the hinge lower surface 596 is large enough in comparison to the gap 590 to provide a degree of securement of the flexible hinge body 545 a so that the respective side portion 546 b , 546 c is retained between the hinge support flange 586 a , 586 b and the respective bottom surface 538 a , 538 b of the respective rigid panel 536 a , 536 b .
- the hinge thickness 545 d at the respective intermediate portion 546 d , 546 e is greater than the gap 590 , thereby reducing the possibility of the respective intermediate portion 546 d , 546 e passing through the gap 590 due to movements and stresses anticipated in use of the folding tonneau cover apparatus 510 .
- the adhesive 570 a (such as the double-sided adhesive tape 571 a , for example), the adhesive 570 a provides further securement of the flexible hinge body 545 a to the respective rigid panels 536 .
- adhesive 570 a is preferably located between each side portion 546 b , 546 c and the respective rigid panel 536 ( 536 a , 536 b , 536 c , 536 d ) to protect against passage of debris or precipitation into the cargo box 5 ; the adhesive 570 a can also aid in securement of the flexible hinge body 545 a to the respective rigid panel 536 .
- the side portions 546 b , 546 c can fit tightly between the respective extended flange or hinge support flange 586 ( 586 a , 586 b ) and the respective rigid panel 536 , to provide a degree of protection against passage of debris or precipitation into the cargo box 5 .
- the folding cover assembly 530 preferably includes support bows or channels 550 ( 550 a , 550 b , 550 c , 550 d , 550 e , 550 f , 550 g ) secured to the underside 538 ( 538 a , 538 b , 538 c , 538 d ) of at least some of the rigid panels 536 , near the front edge 541 b and/or the rear edge 541 c of the respective rigid panels 536 , and which extend between the driver's side and the passenger side of the rigid panels 536 .
- the support bows 550 are preferably secured to the underside 538 of the respective rigid panels 536 by adhesive 570 b .
- the support bows 550 include the hinge support flanges 586 .
- the extended flanges 586 are preferably separated a short distance from the respective rigid panel 536 , so that there is a gap 590 between the hinge support flange 586 and the respective rigid panel 536 .
- the hinge support flange 586 and the respective rigid panel 536 form a partial enclosure 592 into which the side portions 546 b , 546 c extend.
- the hinge support flanges 586 each preferably include a raised lip 587 a , 587 b to further secure the flexible hinge body 545 a to the respective rigid panel 536 .
- the raised lip is preferably positioned to create a restricted gap 590 between the raised lip 587 a , 587 b and the respective rigid panel 536 , so that the side portion 546 b , 546 c cannot easily slip out from the partial enclosure 592 through the gap 590 , further securing the flexible hinge body 545 a to the respective rigid panel 536 .
- the intermediate portion 546 b , 546 c preferably has a hinge thickness 545 d which does not permit the intermediate portion 546 b , 546 c to easily pass through the restricted gap 590 , further securing the flexible hinge body 445 a to the respective rigid panel 536 .
- the geometry of the partial enclosure 592 , gap 590 , side portion 546 b , 546 c , and intermediate portion 546 b , 546 c provides a mechanical interlock to secure the flexible hinge body 545 a to the respective rigid panel 536 without the need for adhesive or other fastening mechanism.
- adhesive 570 a is used to secure the flexible hinge body 545 a to the respective rigid panel 536 ; in alternative embodiments, adhesive 570 a is located at an interface between the flexible hinge body 545 a and the hinge support flanges 586 , adhesive 570 a is located at an interface between the flexible hinge body 545 a (at the hinge body upper surface 595 ) and the bottom surface or underside 538 of the respective rigid panel 536 , or adhesive 570 a is located both at an interface between the flexible hinge body 545 a (at the hinge body lower surface 596 ) and the hinge support flanges 586 and at an interface between the flexible hinge body 545 a and the bottom surface or underside 538 of the respective rigid panel 536 .
- a mechanical interlock together with adhesive 570 a secures the flexible hinge body 545 a to the respective rigid panel 536 .
- the mechanical interlock includes the geometry of the intermediate portion and the geometry of the lip.
- the flexible hinge body 545 a preferably includes polymer material 547 a , which more preferably includes an elastomeric polymer material 547 b .
- a single type of elastomeric polymer material 547 b is used in the central portion 546 a , side portions 546 b , 546 c , and intermediate portions 546 d , 546 e of the flexible hinge body 545 a .
- the flexible hinge body 545 a includes a plurality, i.e.
- more than one type of polymer material 547 a which differ in elastic properties; for example, a more flexible elastomeric polymer material 547 c may be preferably incorporated in the central portion 546 a and a stiffer elastomeric polymer material 547 d may be preferably incorporated in the side portions 546 b , 546 c .
- the intermediate portion 546 d , 546 e may include an intermediate polymer material 547 e which may be a mixture or combination of the more flexible elastomeric polymer material 547 c and the stiffer elastomeric polymer material 547 d , and may provide a transition from the more flexible elastomeric polymer material 547 c to the stiffer elastomeric polymer material 547 d .
- the flexible hinge body 545 a includes more than one type of polymer material to provide for more optimal properties in the various portions; for example, a more flexible elastomeric polymer material 547 c may be utilized advantageously in the central portion 546 c to provide for bending of the flexible hinge body 545 a when folding or unfolding the folding cover assembly 530 , while a stiffer elastomeric polymer material 547 d may be utilized advantageously in the side portion 546 b , 546 c to provide for securement of the flexible hinge body 545 a to the respective rigid panel 536 .
- the flexible hinge body 545 a is fabricated by co-extruding the more than one type of polymer material 547 a to form the flexible hinge body 545 a of materials which vary along the hinge body profile 545 c but which are generally the same along the hinge longitudinal axis 545 b of the flexible hinge body 545 a.
- the folding cover assembly 230 can be placed onto the side rails 520 and unfolded as schematically illustrated in FIG. 19 C , beginning with (1) placing the bundled folding cover assembly 530 on the side rails 520 with the hooks 562 at the front of the front panel 536 c aligned with the respective catches 564 on the respective side rails 520 ; (2) lowering the folding cover assembly 530 onto the side rails 520 until the latches 552 at the rear of the front panel 536 c are engaged with the side rail lip 524 of the respective side rails 520 and the containment brackets 525 a and 525 b .
- the bundled folding cover assembly 530 can be left secured in this configuration, or if it is desired to unfold the folding cover assembly 530 to cover the cargo box 5 , the strap brackets 543 b can be disengaged from the bracket slots 543 c , and (3) the middle panel 536 b can be rotated rearward onto the side rails 520 , with the hooks 562 at the front of the middle panel 536 b engaging the respective catches 564 , and (4) the rear panel 536 a can be rotated rearward onto the side rails 520 , with the hooks 562 at the front of the rear panel 536 a engaging the respective catches 564 and the latches 552 at the rear of the rear panel 536 a engaging with the side rail lip 524 of the respective side rails 520 .
- FIGS. 20 A- 20 E are schematic illustrations of the folding tonneau cover apparatus 510 for various configurations of cargo box 5 geometries as may be found on various trucks 2 .
- Preferred embodiments of the folding cover assembly 530 include the rear panel 536 a , the middle panel 536 b , the front panel 536 c , and the spacer panel 536 d , as previously described.
- FIGS. 20 A- 20 E are schematic illustrations of the folding tonneau cover apparatus 510 for various configurations of cargo box 5 geometries as may be found on various trucks 2 .
- Preferred embodiments of the folding cover assembly 530 include the rear panel 536 a , the middle panel 536 b , the front panel 536 c , and the spacer panel 536 d , as previously described.
- the overall length 533 of the folding cover assembly 530 is shown for each example, and the length 539 of each of the panels 536 a - 536 d is indicated as 539 a - 539 d , respectively, and the width 540 of the panels 536 a - 536 d is indicated as 540 a - 540 d , respectively, and the side angle 542 of the panels 536 a - 536 d is indicated as 542 a - 542 d , respectively.
- Panels 536 a - 536 c can have similar length 539 a - 539 c , or the length of some or all of panels 536 a - 536 c can differ.
- Panel 536 d can have a similar length 539 d as panels 536 a - 536 c , but preferably the length 539 d of panel 536 d is substantially smaller than the lengths 539 a - 539 c of panels 536 a - 536 c .
- Panels 536 a - 536 d can have similar width 540 , or the width of some or all of panels 536 a - 536 d can differ.
- Panels 536 a - 536 d can have the same side angle 542 , or the side angle 542 a - 542 d of some or all of panels 536 a - 536 d can differ.
- FIG. 20 A shows the folding cover assembly 530 as configured for a cargo box having angled sides; since this example folding cover assembly 530 has angled sides, the width 540 is different at the front and rear of a panel.
- the width 540 of the rear panel 536 a at the rear of the rear panel 536 a is labeled 540 a ′, to distinguish it from the width 540 a of the rear panel 536 a at the front of the rear panel 546 a .
- the width 540 of the panel 536 b at the rear of the panel 536 b is similar to the width 540 a of the panel 536 a at the front of the panel 536 a , and so forth.
- FIG. 20 B is a schematic illustration of the folding cover assembly 530 as configured for a cargo box having parallel sides; in this example, the width 540 of each of the panels is similar.
- FIG. 20 C is a schematic illustration of the folding cover assembly 530 as configured for an elongated cargo box; in this example, the overall length 533 is longer than in the example of FIG. 20 B .
- FIG. 20 D is a schematic illustration of the folding cover assembly 530 as configured for a shorter cargo box; in this example, the overall length 533 is shorter than in the example of FIG. 20 B .
- FIG. 20 C is a schematic illustration of the folding cover assembly 530 as configured for an elongated cargo box; in this example, the overall length 533 is longer than in the example of FIG. 20 B .
- FIG. 20 D is a schematic illustration of the folding cover assembly 530 as configured for a shorter cargo box; in this example, the overall length 533 is shorter than in the example of FIG. 20 B .
- 20 E is a schematic illustration of the folding cover assembly 530 as configured for a cargo box with arbitrary shape; in this example, the sides of the panels 536 are angled, and the rear of the rear panel 536 a is curved, extending a curved extension distance 539 e in the central portion with respect to the side portions of the rear panel 536 a .
- the folding cover assembly 530 can be configured for a variety of other configurations of truck box 5 , with any of the panels 536 a - 536 d configured with straight or angled or curved shapes such as those illustrated in the examples of FIGS. 20 A- 20 E , in various combinations.
- FIGS. 21 A and 21 B Further advantages to the structure described herein of the flexible hinge 544 are illustrated in FIGS. 21 A and 21 B .
- the hinge 544 as described herein is low profile, reducing the overall thickness, bulk, and weight of the folding cover assembly 530 .
- the flexible hinge 544 can tolerate some deformation, so that if adjacent panels 536 are not aligned perfectly, or are not perfectly flat, the hinge 544 can still function to allow the folding cover assembly 530 to fold without binding.
- the configuration disclosed herein of hinge 544 can accommodate panels 536 , some of which are preferably slightly bowed as described herein and illustrated in FIG. 16 E .
- FIG. 21 A is a schematic illustration of a portion of the folding tonneau cover apparatus 510 showing a respective flexible hinge 544 interconnecting two respective adjacent panels 536 , showing bent or bowed support bows 550 creating a bending or bowing of the panels 536 attached thereto (see also FIGS. 16 B- 16 E ), with the bending or bowing exaggerated for illustration, with the panels 536 unfolded.
- FIG. 21 B is a schematic illustration similar to that of FIG. 21 A , showing the two respective adjacent panels 536 folded up in the direction indicated by the arrow.
- FIGS. 21 A- 21 B illustrate how the flexible hinge 544 can accommodate the folding up and unfolding of such bent or bowed panels 536 .
- FIG. 22 is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus 410 having a folding cover assembly 430 incorporating a cab panel 436 e onto which the rear, middle, spacer, and front panels 436 a , 436 b , 436 d , and 436 c , respectively, can fold, with the folding tonneau cover apparatus 410 attached to a pickup truck 2 which is shown in phantom.
- FIG. 23 is a bottom plan view of the folding tonneau cover apparatus 410 of FIG. 22 . Visible in this view are hinges 444 , which are situated between adjacent panels 436 and adjoin adjacent panels 436 .
- Each panel 436 has a top surface 437 and a bottom surface or underside 438 ;
- panel 436 a has a top surface 437 a and a bottom surface or underside 438 a
- panel 436 b has a top surface 437 b and a bottom surface or underside 438 b
- panel 436 c has a top surface 437 c and a bottom surface or underside 438 c
- panel 436 d has a top surface 437 d and a bottom surface or underside 438 d
- panel 436 e has a top surface 437 e and a bottom surface or underside 438 e .
- hinges 444 are specifically referenced herein as 444 a - 444 d , and non-specifically or collectively referenced as 444 .
- hinge 444 a situated between the rear panel 436 a and the middle panel 436 b is hinge 444 a .
- hinge 444 b situated between the middle panel 436 b and the spacer panel 436 d is hinge 444 b
- hinge 444 c situated between the spacer panel 436 d and the front panel 436 c
- situated between the front panel 436 c and the cab panel 436 e is hinge 444 d .
- Hinges 444 allow the folding cover assembly 430 to be folded up and will be more fully described below.
- hinge guards 463 are shown; hinge guards 463 provide additional support to the hinges 444 when the folding cover assembly 430 is unfolded and in place covering the cargo box 5 of truck 2 ( FIG. 22 ). Hinge guards 463 also provide protection against slicing through the hinges 444 ; further description of the hinge guards 463 is provided herein.
- Support bows 450 are attached to the panels 436 to provide additional support and rigidity to the panels 436 , and also provide a structure for mounting of various other components as described in detail herein. For ease of discussion, support bows 450 are specifically referenced herein as 450 a - 450 i , and non-specifically or collectively referenced as 450 .
- bow end caps are preferably secured to each end of the support bows 450 .
- the folding tonneau cover apparatus 410 is removably secured to the support frame assembly 418 by securing apparatus 451 a .
- securing apparatus 451 a includes at least one locking member 451 b which is engageable and disengageable from the support frame assembly 418 .
- the locking member 451 b includes latches 452 which are located at the support bows as shown and secure the folding cover assembly 430 to the side rails 420 a and 420 b .
- the latches are similar to latches 552 , 652 , 752 shown and described herein, and preferably include a latch slide with inclined bottom surface, an engaging portion, a spring, and a spring retainer, similar to corresponding elements 653 , 653 a , 653 b , 656 , 657 , and 657 a of latches 562 , for example, shown and described herein and illustrated in FIG. 33 B and elsewhere herein.
- Release cords 454 are attached to the latches 452 .
- release cords 454 are specifically referenced herein as 454 a , 454 d , and 454 f , and non-specifically or collectively referenced as 454 .
- the release cords 454 pass through cord guides 455 which are attached to support bows 450 as shown.
- the cord guides 455 can be retainer cord guides 455 b , which are similar to retainer cord guides 555 b illustrated in FIG. 11 B .
- the cord guides are non-specifically or collectively referenced herein as 455 , but cord guides 455 c - 455 d are specifically referenced herein to facilitate the detailed description herein.
- Standoffs 458 are shown, and are described in further detail herein.
- Perimeter seal 434 is located on the bottom 432 b of the folding cover assembly 330 and is arranged to seal against the sidewalls 6 a and 6 b and the front wall 6 c and the tailgate 6 d of the cargo box 5 ; some portions of perimeter seal 434 are behind side rails 420 a and 420 b and not visible in FIG. 23 .
- the perimeter seal 434 is further described herein.
- Clamps 414 secure the side rails 420 a and 420 b to the sidewalls 6 a and 6 b of the cargo box 5 in a similar manner as other clamps 514 , 614 , 714 described herein.
- the support bows or transverse frame members or channels 450 provide additional support for the panels 436 .
- the panels each have two support bows 450 , one located near each of the front and rear ends of each panel 436 , except for the spacer panel 436 d , which has only a single support bow 450 .
- the latches 452 engage the side rails 420 a and 420 b to secure the folding cover assembly 430 , and can slide a short distance towards or away from the side rails 420 a and 420 b to engage or release the folding cover assembly 430 or selected panels 436 or portions thereof from the side rails 420 a and 420 b as further described herein.
- there are three latch release cords or release cords or cords 454 each of which are connected to opposing pairs of latches 452 which secure the panels 436 to the side rails 420 a and 420 b .
- the release cords 454 pass through cord guides 455 which are mounted to the support bows 450 ; the release cords 454 can slide within the cord guides 455 .
- the release cords 454 generally extend from the latches 452 along the support bows 450 .
- the release cords 454 can be actuated to release each pair of latches 452 by a driver or operator 8 when desired, to open the folding cover assembly 430 .
- Also seen on FIG. 23 are optional hinge guards 463 ; the optional hinge guards 463 are preferably attached to one of the support bows 450 adjacent to each of the respective hinges 444 . In this example, the hinge guards 463 are shown attached to the support bows 450 b , 450 d , and 450 f .
- hinge guards 463 can be attached to the support bow 450 g or 450 h to provide support for the hinge 444 d in a similar manner.
- the hinge guards 463 provide support for the hinges 444 , such as to support weight or pressure applied to the hinges 444 , the panels 436 , or other portions of the folding cover assembly 430 .
- the hinge guards 463 can also provide some protection against cutting through a hinge 444 to enter the cargo box 5 .
- hooks 462 are attached to some of the support bows 450 .
- hooks 462 are located adjacent each end of each of the support bows 450 b , 450 d , and 450 i , and are aligned with respective catches 464 which are attached to the side rails 420 a and 420 b as illustrated.
- the hooks 462 are engaged with the catches 464 and help to secure the folding cover assembly 430 to the side rails 420 a and 420 b .
- hooks 462 When a panel 430 is rotated upward, the hooks 462 disengage from the catches 464 , allowing the panel to be rotated and stacked onto other panels 430 , as shown herein.
- the hooks 462 slide into the support bows 450 and are secured in position; preferably, the hooks 462 are secured by an interference fit with the support bows 450 , but other securement mechanisms can be utilized, such as screws or other fasteners or adhesives known in the art, or a combination of securement mechanisms.
- hooks and catches such as hooks 462 and catches 464 are located along selected support bows 450 , 550 , 650 , 750 .
- hooks 462 a and 462 b are located near the driver's side end and passenger side end, respectively, of support bow 450 b (near the front end of the rear panel 436 a ), hooks 462 c , 462 d on support bow 450 d (near the front end of the middle panel 436 b ); hooks 462 g and 462 h are located near the driver's side end and passenger side end, respectively, of support bow 450 i (near the front of the cab panel 436 e ).
- the various latches 452 and hooks 462 engage the catches 464 and the side rails 420 a and 420 b to secure the folding cover assembly 430 to the side rails 420 a and 420 b and thereby to the cargo box 5 in order to cover the cargo box 5 when desired, but can be disengaged as described herein to open the folding cover assembly 430 to enter the cargo box 5 when desired.
- the containment brackets 425 a , 425 b are shown, which help to secure the folding cover assembly 430 in position on the side rails 420 a .
- the containment brackets 425 a ′, 425 b ′ are shown, which help to secure the folding cover assembly 430 in position on the side rails 420 a , 420 b especially when the folding cover assembly 430 is in a folded configurations such as those illustrated in FIGS. 30 , 31 A- 31 E .
- the containment brackets 425 a , 425 b can be omitted, as long as the containment brackets 425 a ′, 425 b ′ are present.
- the tonneau cover apparatus 410 includes containment brackets 425 a , 425 b , 425 a ′ and 425 b′.
- FIG. 24 is a partial section view of the rear portion of the folding tonneau cover apparatus 410 of FIG. 22 as indicated on FIG. 23 and illustrating the edge guard 434 i at the rear portion of the rear panel 436 a .
- the folding cover assembly 430 includes a perimeter seal 434 , such as the perimeter seal 434 a (or other perimeter seals shown in FIGS. 15 A- 15 E, 15 G , for example) around substantially the entire perimeter, attached to the bottom surface 438 of each respective panel as described with regard to other embodiments herein.
- the folding cover assembly 430 also includes the edge guard 434 i (such as the edge guard 34 i shown in FIG. 15 F ) at the rear portion of the rear panel 436 a . This edge guard will minimize potential contusions or abrasions that may arise to an operator 8 , if the operator 8 accidentally allows one or more of his or her fingers to rest of the top of the tailgate when securing the rear panel to the respective side rails.
- hinges 444 include flexible sheet material or flexible material 447 which is attached to each of the adjacent panels 436 (specifically, respective adjacent panels of 436 a - 436 d as described herein).
- Flexible sheet material 447 is moisture resistant to avoid leakage into the cargo box 5 .
- Flexible sheet material 447 can include fabric, or a polymeric layer, and may have a reinforcing fiber which can be separate fibers, long (generally continuous) or short (generally discrete) fibers, fibrous yarns, or a web material, or woven material, single-axis or biaxial oriented fibers, or a braid or a felt of fibers, for example.
- flexible material 447 can be a vinyl material, preferably a polyvinyl chloride or PVC covered fabric, a fiber-reinforced rubber or other flexible polymeric material, or a fabric having a water-resistant coating or impregnation.
- the flexible material 447 can be cloth-inserted EPDM rubber, cloth-inserted neoprene rubber, nylon cloth reinforced nitrile rubber, fiberglass-reinforced silicone rubber, polyester-reinforced neoprene sheet, nylon-reinforced neoprene sheet, and other materials available from multiple sources; information regarding example materials is available from www.rubbersheetroll.com and from www.mscdirect.com; note that not all materials listed on those web sites would be preferred for this application.
- a variety of materials could be used as flexible hinge material, such as neoprene, EPDM, flexible PVC, nitrile, natural rubber, flexible thermoplastics, silicone, latex, Hypalon rubber, butyl rubber, recycled rubber, Viton rubber, Santoprene rubber, Skirtboard rubber, SBR rubber, and so forth, that can be used in conjunction with a reinforcing fiber such as EPDM, Nylon, polyester, fiberglass, carbon fiber, aramid fibers, boron fibers, metal fibers, cellulose, wood-derived fibers, and so forth can be used for the flexible hinge material 447 .
- a reinforcing fiber such as EPDM, Nylon, polyester, fiberglass, carbon fiber, aramid fibers, boron fibers, metal fibers, cellulose, wood-derived fibers, and so forth can be used for the flexible hinge material 447 .
- the hinge or flexible hinge 444 is preferably made of a flexible material that can withstand deformation without failure due to cracking or breakage and that is selected from the group consisting of a laminated polymeric material, a fiber-reinforced polymeric material, an elastomeric material, a woven material and a laminated material that is includes a woven material and a moisture-resistant polymeric material.
- a hinge material 447 is chosen that can be heat bonded to the thermal adhesive tape 471 a such as 3M 5933 from 3M, St. Paul, Minn. described herein. Other considerations in choosing an acceptable flexible hinge material 447 are durability over time and resistance to environmental factors such as precipitation, sunlight, temperature ranges, and physical stresses such as impacts and abrasions.
- the flexible material 447 is polyester fiber reinforced polymeric material. More preferably, flexible material 447 is PVC-coated woven polyester material such as part number 90749 available from Lakeview Industries, Chaska, Minn.
- Attachment of the flexible sheet material 447 to the panels 436 is preferably by an adhesive 470 a which may include a layer or coating of adhesive or a double-sided adhesive tape 471 a for example.
- a contact adhesive, or a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a combination can be used to attach the flexible sheet material 447 to the panels 436 , 436 .
- Double-sided adhesive tape 471 a can include an acrylic foam material 472 a , with adhesive layer 472 b arranged on one side of the acrylic foam material 472 a , and adhesive layer 472 c arranged on the other side of the acrylic foam material 472 a for example.
- the adhesive 470 a includes a double-sided adhesive tape 471 a such as 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), wherein the double-sided adhesive tape 471 a is an acrylic foam tape having an acrylic foam material 472 a and an adhesive layer 472 b which includes heat-activated adhesive and an adhesive layer 472 c which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 472 c .
- thermo adhesive tape such as 3M 5933 from 3M, St. Paul, Minn.
- the double-sided adhesive tape 471 a is an acrylic foam tape having an acrylic foam material 472 a and an adhesive layer 472 b which includes heat-activated adhesive and an adhesive layer 472 c which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 472 c .
- the adhesive layer 472 b (in this example, heat-activated adhesive) is aligned with the flexible sheet material 447 while the heat-activated adhesive is activated to adhere the double-sided adhesive tape 471 a to the flexible sheet material 447 ; the flexible sheet material 447 together with the attached double-sided adhesive tape 471 a is subsequently aligned with the panel 436 and the release strip is removed.
- the adhesive layer 86 c is aligned with the panel 436 the flexible sheet material 447 is attached to the panel 436 by activating the adhesive layer 472 c (in this example, pressure-sensitive adhesive).
- the adjacent panel 436 is similarly attached to the flexible sheet material 447 with double-sided adhesive tape 472 a forming the structure of hinge 444 as shown in FIG. 25 B .
- the flexible sheet material 447 allows hinges 444 to take a flat or open configuration as illustrated in FIGS. 25 A and 25 B , or to flex or bend as illustrated in FIGS. 25 C, 26 and 27 , providing a hinge 444 that allows the folding cover assembly 430 to fold as illustrated throughout the Figures and described herein, with panels 436 folding up and rotating towards other panels as shown.
- the flexible sheet material 447 is adhered to the respective bottom or underside 438 of the panels 436 (specifically, the underside 438 a - 438 d of respective adjacent panels of 436 a - 436 d as described herein) of the folding cover assembly 430 as shown.
- the hinges 444 are securely attached to the respective panels 436 , are sealed to prevent water or debris from entering the cargo box through the folding cover assembly 430 at the hinges 444 , and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box 5 would be exposed.
- the hinge 444 is low profile, so that the thin structure provides an effectively continuous seal along the perimeter seal 434 to prevent ingress of precipitation or debris or loss of contents from the cargo box 5 , or lifting of the folding cover assembly by the wind under normal circumstances.
- All of the respective seals that are disclosed herein and can be used as a perimeter seal 434 are water resistant, preferably water proof such that water cannot flow through the seal material and is prevented from egress into the cargo box 5 through the respective seal material.
- the perimeter seal 434 will be secured with an adhesive material to the underside of each of the respective panels proximate an outer portion of each of the respective panels and an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels, so that the passage of moisture through the juncture of any areas where such bonding occurs is minimized, if not entirely prevented.
- the perimeter seal 434 when the perimeter seal 434 is secured to each of the respective rigid panels proximate an outer portion of each of the respective panels and to an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels and compressed between the outer edges of each of the respective panels and each of the respective side rails 420 a , 420 b , the top of the tailgate 6 d and the top of front wall 6 c , wherein the cover assembly 430 is fully secured to the support frame assembly 418 , the perimeter seal 434 will act to minimize the egress of moisture, wind and debris into the cargo box 5 , preferably completely preventing moisture, wind and debris of any kind from entering the cargo box 5 when the cover assembly is fully secured to the support frame and the pickup truck.
- FIG. 25 B also schematically illustrates support bows 450 which are preferably attached to respective panels 436 by an adhesive 470 b , which may include a layer or coating of adhesive or a double-sided adhesive tape 471 b , for example.
- an adhesive 470 b which may include a layer or coating of adhesive or a double-sided adhesive tape 471 b , for example.
- Double-sided adhesive tape 471 b preferably includes an acrylic foam material 472 d , with adhesive layer 472 e arranged on one side of the acrylic foam material 472 d , and adhesive layer 472 f arranged on the other side of the acrylic foam material 472 d , for example.
- the adhesive 470 b includes a double-sided adhesive tape 471 b such as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sided adhesive tape 471 b is an acrylic foam tape having an adhesive layer 472 e which includes pressure-sensitive adhesive and having an adhesive layer 472 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 472 f .
- pressure adhesive tape such as 3M CV62F from 3M, St. Paul, Minn.
- the adhesive layer 472 e (in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface 474 d of the support bow 450 to adhere the double-sided adhesive tape 471 b to the support bow 450 ; the support bow 450 together with the attached double-sided adhesive tape 471 b is subsequently aligned with the panel 436 and the release strip is removed.
- the adhesive layer 472 f is then aligned with the panel 436 , and the support bow 450 is attached to the respective panel 436 by activating the adhesive layer 472 f (in this example, pressure-sensitive adhesive).
- any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material is also preferable but not always required.
- a single layer of adhesive could be used, similar to the arrangement shown in FIG. 55 A .
- Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J.
- the sidebars or handles 459 are preferably also attached to the underside 438 of the respective panels 436 , preferably in a similar manner as that just described for the support bow 450 .
- adhesive 470 b can be applied at selected portions of the length of the support bow 450 or the sidebar 459 , adhesive 470 b is preferably applied along substantially the entire length of the support bow 450 and the sidebar 459 , to enhance stability and to minimize unwanted vibrations.
- the sidebars 459 , support bows 450 , or the flexible sheet material 447 of hinges 444 can be attached to the panels 436 with adhesives such as glue, or with fasteners, or spot welds.
- FIG. 26 is a schematic illustration showing the hinge of FIG. 5 B but with the hinge folded about 180 degrees.
- FIG. 27 is a schematic illustration showing a cross section similar to that of FIG. 25 C but showing a spacer panel and two adjacent hinges of the folding tonneau cover of FIG. 22 illustrating both hinges in a partially folded configuration.
- FIG. 28 is a schematic illustration showing a preferred embodiment of general steps and configurations of the folding cover assembly of FIG. 22 as it is folded up or unfolded.
- the hinge 444 a flexes to allow the rear panel 436 a to fold up, passing through 90 degrees (configuration 2 ) towards the middle panel 436 b , and fold over onto the middle panel 436 b (configuration 3 ).
- the hinge 444 b flexes to allow the middle panel 436 b (together with the rear panel 436 a which is folded onto the middle panel 436 b ) to fold up, passing through 90 degrees (configuration 4 ) towards the spacer panel 436 d , passing through a point at which standoffs 458 contact the front panel (configuration 5 ).
- hinge 444 b flexes back towards 90 degrees as hinge 444 c flexes to allow the spacer panel 436 d to fold up, and continue to fold over (together with the rear panel 436 a which is folded onto the middle panel 436 b , and the middle panel 436 b ) towards the front panel 436 c (configuration 6 ), until the rear panel 436 a , middle panel 436 b , and spacer panel 436 d are folded onto the front panel 436 c (configuration 7 ).
- the hinge 444 d flexes to allow the rear panel 436 a , middle panel 436 b , spacer panel 436 d , and front panel 436 c to fold up into a generally vertical orientation onto the cab panel 444 d (configuration 8 ).
- the hinge 444 d flexes further to allow the rear panel 436 a , middle panel 436 b , spacer panel 436 d , and front panel 436 c , folded up onto the cab panel 444 d , to be secured near or adjacent or touching the cab (configuration 9 ) with folded cover forward securing assembly 419 , including various securing members 465 as are described below.
- FIG. 28 is a schematic overview of the general folding of the folding cover assembly 430 ; the various configurations are further illustrated and described elsewhere herein in greater detail in relation to the folding cover assembly 430 or other folding cover assemblies 530 , 630 described herein.
- FIG. 29 is a side perspective view from the driver's side of the folding tonneau cover apparatus 410 of FIG. 22 , showing a configuration in which the rear panel 436 a , the middle panel 436 b , and the spacer panel 436 d are folded onto the front panel 436 c and secured with storage straps 494 a .
- the various mechanisms and methods in releasing latches 450 , disengaging hooks 462 from catches 464 , bending the hinges 444 , rotating and folding up of panels 436 of the folding cover assembly 430 to the configuration of FIG. 29 are generally similar to those described herein in relation to folding cover assemblies 530 and 630 , and particularly similar to that of the folding cover assembly 630 described herein.
- the storage straps 494 a can attach to the panel brackets 466 which are attached to the top surface 437 e of the cab panel 436 e .
- the folding cover assembly 430 can be further folded up onto the cab panel 436 e as illustrated in FIG. 30 , and panel brackets 466 also provide support to the panels 436 a , 436 b , 436 c , 436 d as seen in FIGS. 30 - 31 E .
- This configuration allows entry into a substantial portion of the cargo box 5 . If entry into a greater portion of the cargo box 5 is desired, then the folding cover assembly 430 can be folded up onto the cab panel 436 e as shown in FIG.
- the driver or operator 8 can pull release cord 454 f to release the latches 452 k and 452 m at the ends of the support bow 450 h at the rear of the cab panel 436 e , disengaging them from the side rails 420 a , 420 b and the containment brackets 425 a ′, 425 b ′ in a manner similar to that already described herein with regard to other latches 552 , 652 , 752 .
- the driver or operator 8 can pull release cord 454 f to release the latches 452 k and 452 m at the ends of the support bow 450 h at the rear of the cab panel 436 e , disengaging them from the side rails 420 a , 420 b and the containment brackets 425 a ′, 425 b ′ in a manner similar to that already described herein with regard to other latches 552 , 652 , 752 .
- the rear panel 436 a , the middle panel 436 b , the front panel 436 c and the spacer panel or hinge panel 436 d are folded together and are turned upward on top of the cab panel 436 e , with the rear panel 436 a , the middle panel 436 b , and the front panel 436 c , oriented in a generally vertically orientation while resting upon the cab panel 436 e.
- the folding cover assembly 430 can be secured in the generally vertical position with the with the rear panel 436 a , the middle panel 436 b , and the front panel 436 c , oriented generally vertically, by securing member(s) 465 (such as cab strap 465 a , side strap 465 b , cab panel strap 465 c , securing magnet 465 d , or securing bracket 465 e ) that are used to secure the folding cover assembly 430 in this configuration, as illustrated in FIGS. 31 A- 31 E . In some of the configurations illustrated in FIGS.
- FIG. 31 A illustrates cab straps 465 a which are secured to cab brackets 467 a which are preferably secured to the cab 4 by adhesive such as adhesives 70 a , 470 b , 471 a , 471 b , or other adhesives described herein.
- FIG. 31 B illustrates a side strap 465 b which secures the folding cover assembly 430 in position as shown.
- a side strap 465 b can be provided on both the driver's side and the passenger side, or on only one side.
- the side strap 465 b can form a single long loop which passes through the cab 4 (such as by temporarily opening the doors or the windows of the cab).
- the side strap 465 b can attach using a buckle to a separate strap which is secured inside the cab 4 .
- FIG. 31 C illustrates a cab panel strap 465 c which secures the folding cover assembly 430 in position as shown.
- a cab panel strap 465 c can be provided on both the driver's side and the passenger side, or on only one side.
- the cab panel strap 465 c can attach to the cab panel 436 e ; alternatively, the cab panel strap 465 c can attach using a buckle to a separate strap which is secured to the cab panel 436 e.
- FIG. 31 D illustrates a securing magnet 465 d which secures the folding cover assembly 430 in position as shown.
- a single securing magnet 465 d can be provided or a plurality of securing magnets 465 d can be provided.
- the securing magnet 465 d can magnetically attach to a cab magnet 467 b for securement to the cab 4 .
- the securing magnet 465 d can magnetically attach to a portion of the cab 4 .
- FIG. 31 E illustrates a securing bracket 465 e which secures the folding cover assembly 430 in position as shown.
- a securing bracket 465 e can be provided on both the driver's side and the passenger side, or on only one side.
- the securing bracket 465 e can retain the middle panel 436 b and the front panel 436 c and the cab panel 436 e in the illustrated configuration (with the rear panel 436 a and spacer panel 436 d also held since they are attached to the other panels 436 by the hinges 444 ).
- the securing bracket 465 e can attach to the respective support bows 450 to secure the folding cover assembly in the illustrated configuration.
- the securing bracket 465 e attaches to the panel bracket 466 .
- FIGS. 32 - 40 H Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated in FIGS. 32 - 40 H .
- a rear perspective view of a folding tonneau cover apparatus 610 is illustrated in FIG. 32 , which includes a support frame assembly 618 , a folded cover forward securing assembly 619 , and a folding cover assembly 630 incorporating a cab panel 636 e onto which rear panel 636 a , middle panel 636 b , spacer panel 636 d , and front panel 636 c can fold, with the folding tonneau cover apparatus 610 attached to a pickup truck 2 which is shown in phantom, with a cab 4 , a drivers side 3 a , a passenger side 3 b , a front 3 c , and a rear 3 d .
- the folding tonneau cover apparatus 610 is secured to the truck 2 to cover a cargo box 5 having a drivers side sidewall 6 a , a passenger side sidewall 6 b , a front wall 6 c ( FIG. 40 ), and a tailgate 6 d , which define a top opening 6 f ( FIG. 40 ), a cargo box length 7 a , and a cargo box width 7 b .
- the panels 636 are secured to side rails 620 a , 620 b by latches 652 , of which latches 652 a and 652 b are partially shown on FIG. 32 .
- the folding cover assembly 630 has a top 632 a and a bottom 632 b.
- the folded cover forward securing assembly 619 secures the folded folding cover assembly 630 in an upright folded orientation in which the top or upper surface 637 a , 637 b , 637 c of the rear panel 636 a , middle panel 636 b , front panel 636 c , respectively, are in an upright or generally vertical orientation.
- the folded cover forward securing assembly 619 preferably includes two cab bracket assemblies 667 c , two cab braces 668 a , two storage retainers 643 e , and two storage straps 643 d .
- the folded cover forward securing assembly 619 can include other elements such as the securing members 465 disclosed herein, including the cab strap 465 a , the side strap 465 b , the cab panel strap 465 c , the securing magnet 465 d , the securing bracket 465 e the panel bracket 466 , the cab securement member 467 , the cab bracket 467 a , the cab magnet 467 b ( FIGS. 29 - 31 E ) or combinations of the elements disclosed herein.
- the securing members 465 disclosed herein including the cab strap 465 a , the side strap 465 b , the cab panel strap 465 c , the securing magnet 465 d , the securing bracket 465 e the panel bracket 466 , the cab securement member 467 , the cab bracket 467 a , the cab magnet 467 b ( FIGS. 29 - 31 E ) or combinations of the elements disclosed herein.
- FIG. 32 A A top plan view of the folding cover assembly 630 is illustrated in FIG. 32 A , which shows the panels 636 , namely the rear, middle, front, spacer, and cab panels 636 a , 636 b , 636 c , 636 d , 636 e , each having a top surface 637 a , 637 b , 637 c , 637 d , 637 e , and a width 640 , namely 640 a , 640 b , 640 c , 640 d , 640 e , respectively, and a length 639 , namely 639 a , 639 b , 639 c , 639 d , 639 e , respectively; the folding cover assembly 630 has a length 633 , and a gap 641 between adjacent panels 636 .
- the folding cover assembly 630 preferably includes storage retainers 643 e attached to the cab panel 636 e.
- FIG. 32 B A bottom plan view of the folding tonneau cover apparatus 610 is illustrated in FIG. 32 B , which shows the folding cover assembly 630 , the bottom surfaces 638 a , 638 b , 638 c , 638 d , 638 e of panels 636 a , 636 b , 636 c , 636 d , 636 e , respectively, and support bows 650 a , 650 b , 650 c , 650 d , 650 e , 650 f , 650 g , 650 h , latches 652 a , 652 b , 652 c , 652 d , 652 e , 652 f engaged with side rails 620 a , 620 b , and with latches 652 e and 652 f also engaged with containment brackets 625 a , 625 b which aid in maintaining the position of the folding cover assembly 630 with
- Handles 659 are attached to the bottom surfaces 638 of panels 636 a , 636 b , and 636 c , preferably by adhesive 670 b , such as double-sided adhesive tape 671 b or by other adhesive elements such as are described herein.
- Standoffs 658 are preferably attached to handles 659 that are attached to the rear panel 636 a as shown; the standoffs 658 are preferably attached similar to the attachment of standoffs 558 to support bows 550 as illustrated in FIGS. 14 A- 14 C .
- the folding cover assembly 630 preferably includes perimeter seal 634 located at the perimeter of the folding cover assembly 630 ; various configurations of perimeter seal are envisioned, such as the perimeter seals 534 , 534 a - 534 k shown in FIGS. 15 A- 15 H .
- the cab panel 636 e is secured to the side rails 620 a , 620 b by cab panel retainers 679 and retainer bolt 678 ; two retainer bolts are illustrated as examples, including hex bolt 678 a and handle bolt 678 b ( FIG. 32 K ).
- FIG. 32 C A side view of portions of the folding tonneau cover apparatus 610 is illustrated in FIG. 32 C , as viewed from line 32 C— 32 C of FIG. 32 A , and give further understanding of the relative positioning of the elements. Further detailed views of the folding tonneau cover apparatus 610 are illustrated in FIGS. 32 D- 32 F .
- FIG. 32 D shows a portion of the folding tonneau cover apparatus 610 as viewed from line 32 D- 32 D of FIG.
- FIG. 32 A shows a portion of the folding tonneau cover apparatus 610 as viewed from line 32 E- 32 E of FIG. 32 A , illustrating the front hinge 644 d and adjacent panels 636 c , 636 e .
- FIG. 32 E An alternative perimeter seal 634 j , storage retainer 643 e , cab panel retainer 679 , and hex bolt 678 a , are illustrated.
- a tether 680 secured to support bow 650 g (not visible on FIG. 32 E ) by ring 682 , and link 681 are shown, which provide for an additional safety securement when the link is attached to the side rail 620 a at aperture 683 ( FIG. 32 J ) as illustrated on FIGS. 39 C-E , for example.
- the folding tonneau cover apparatus preferably includes the storage retainer 643 e , which is secured to the cab panel 626 e by a retainer fastener 643 k .
- the storage retainer 643 e preferably includes a retainer protrusion 643 h that engages a retainer slot 643 j in the cab panel 636 e to aid in maintaining proper position and orientation of the storage retainer 643 e .
- the storage retainer 643 e also preferably includes a retainer hook 643 f to which a storage strap 643 d can be secured ( FIG.
- FIG. 40 A is an enlarged detailed front perspective view of a portion of the folding tonneau cover apparatus encircled by dashed line 32 F- 32 F of FIG. 32 C , showing a storage retainer and a tether and link.
- FIGS. 32 H-J Portions of the folding tonneau cover apparatus of FIG. 32 are illustrated in FIGS. 32 H-J to show the structure and elements near passenger side of the spacer panel 636 d and the cab panel 636 e .
- Middle panel 636 b , front panel 636 c , and bottom surfaces of the middle panel, front panel, and cab panel, respectively, are shown, with the hook 662 f engaged with the catch 664 f , the latch 652 f engaged with the containment bracket 525 b and the side rail 620 b , cab brace 668 a secured by cab brace fastener assembly 668 d to the support bow 650 e and engaged with cab brace retainer 668 f .
- the release cord 654 c and handles 659 are also shown.
- the tether 680 is secured to support bow 650 g by ring 682 , and is also attached to link 681 which can be attached to side rail 620 b at aperture 683 for additional securement of the folding cover assembly 630 to the side rail 620 b ; similar elements are located at the drivers side of the folding tonneau cover apparatus 610 .
- the retainer fastener 643 k can be seen engaged with the cab panel 636 e .
- the cab panel retainer 679 is engaged with the support bow 650 h and is secured to the side rail 620 b by a retainer bolt 678 , such as retainer hex bolt 678 a , although other fasteners such as retainer handle bolt 678 b ( FIG. 32 K ) can be utilized.
- FIG. 32 K An alternative retainer handle bolt or lever clamp bolt 678 b is illustrated in FIG. 32 K ; also in FIG. 32 K ; the tether 680 is not shown in this view.
- FIG. 33 B is an enlarged partial section view of the driver's side end portion of the support bow 650 a as indicated in FIG. 33 A .
- the cord guides 655 , 655 c are preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer.
- the cord guides 655 can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process.
- the latch 652 a includes latch slide 653 having an engaging portion 653 b which extends forward to engage the lip 624 of the side rail 620 a , so as to secure the panel 630 a to the side rail 620 a .
- the latch slide 653 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used.
- the latch slide 653 includes fiberglass-reinforced nylon.
- the latch slide 653 is biased by a biasing member or spring 656 towards the side rail 620 a so that the engaging portion 653 b engages the side rail 620 a to form a secured configuration in which the respective panel 636 is restricted from being lifted up from the cargo box 5 ;
- the spring 656 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide 653 towards the side rail 620 a so that the engaging portion 653 b engages the side rail 620 a so that the latch 652 is in the secured configuration.
- the spring 656 is held between the latch slide 653 and a spring retainer assembly 657 .
- the spring retainer assembly 657 is secured in the desired location in the support bow 650 a .
- the side rails 620 a and 620 b preferably include extruded metal, and have a side rail engagement portion 622 a , arranged to approximate a portion of the sidewall 6 a , 6 b of the pickup truck 2 .
- the clamp 614 is shown in detail in FIG. 33 B .
- the clamps 614 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.
- Clamps 614 preferably have an outer member 616 a and an inner member 616 b which are tightened towards each other and held as an assembly on the sidewall 6 a by a fastener assembly 616 d which preferably includes a bolt 616 e , a washer 616 f , and a nut 616 g .
- inner member 616 b has a clamp engagement portion 616 c which, together with side rail engagement portion 622 a of side rail 620 a , aids in securing the clamps 614 in place on the side rail 620 a .
- the clamps 614 are arranged and tightened to secure the side rail 620 a to the sidewall 6 a , with a sidewall gasket 622 c arranged between the side rail 620 a and the sidewall 6 a as illustrated.
- a bow end cap 665 is located at the end of the support bow 650 a .
- a release cord 654 and a cord guide 655 are shown, and will be described in further detail herein.
- the side rail engagement portion 622 a is a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of the sidewall 6 a , 6 b . In the example of FIG.
- a portion of the sidewall 6 a of a cargo box 5 of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a side rail engagement portion 622 a along the length of the side rails 620 a and 620 b that are appropriately configured and oriented.
- the cargo box 5 of the pickup truck 2 includes a sidewall cap 6 e , but other cargo boxes 5 lack a sidewall cap.
- a sidewall 6 a and sidewall cap 6 e are similarly illustrated in subsequent drawings herein.
- the side rail engagement portion 622 a has a side rail engagement feature 622 b , such as ridges, knurling, surface patterns or textures, or other features which aid in securing the clamps 614 .
- a sidewall gasket 622 c preferably made of polymeric material is located between the side rail engagement portion 622 a and the sidewall 6 a ; the sidewall gasket 622 c can provide protection against damage to the sidewall 6 a by abrasion against the side rail 620 a . Other flexible material can also be used.
- the sidewall gasket 622 c can provide leak resistance to prevent water, dust, or other debris from passing into the cargo box 5 along the side rail engagement portion 622 a .
- the side rail 620 a has a flange or side rail lip 624 along the length of the side rail 620 a .
- the side rail lip 624 provides support for the folding cover assembly 630 .
- the side rail lip 624 provides a feature for engagement of the engaging portion 653 b of the latches 652 .
- the driver's side portion of the support bow 650 a is shown in FIG. 33 B ; the other end of the support bow 650 a (toward the passenger side) has a mirror-image configuration, with a latch 652 engaging side rail 620 b , and side rail 620 b being attached to sidewall 6 b in a similar manner.
- the release cord 654 a can be pulled, which will retract each of the latches 652 against the force of the respective biasing member or spring 656 .
- the release cord 654 a will be pulled as illustrated in FIG. 34 A , by an operator 8 who has walked to the rear of the cargo box 5 and has opened the tailgate 6 d and reaches in to access and pull the release cord 654 a .
- the engaging portion 653 b of the latch 652 is retracted away from the lip 624 of the side rail 620 a as shown in FIG.
- the cord guides 655 adjacent to the latches 652 help to maintain alignment of the ends of the release cord 654 a so that the latches 652 are retracted in alignment with the support bow 650 a , to avoid excessive friction, wear and potential binding.
- the driver's side portion of the support bow 650 a is shown in FIG.
- the other end of the support bow 650 a (toward the passenger side) has a mirror-image configuration, and when the release cord 654 a is pulled, the latches 652 at both ends of the support bow 650 a are retracted, so that the rear end of the rear panel 636 a can be lifted up from both side rails 620 a and 620 b.
- each of the hinges 644 ( 644 a , 644 b , 644 c , and 644 d ) preferably includes the flexible hinge body 645 a which is elongated and extends between the driver's side 3 a and the passenger side 3 b of the cargo box 5 when the folding cover assembly 630 is unfolded to cover the cargo box 5 .
- the flexible hinge body 645 a is similar to the flexible hinge body 545 a of FIG.
- FIG. 17 C with similar elements and configuration, with a hinge longitudinal axis 645 b which is oriented along the length of the hinge body 645 a , and a hinge body profile 645 c , which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis 645 b (not shown separately; refer to corresponding elements for flexible hinge body 545 a in FIG. 17 C , including the hinge longitudinal axis 545 b which is oriented along the length of the hinge body 545 a , and the hinge body profile 545 c , which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis 545 b ).
- the hinge body profile 645 c is preferably uniform along the hinge longitudinal axis 645 b of the hinge body 645 a .
- each of the flexible hinges 644 can have a similar hinge body profile 645 c .
- the hinge body profile 645 c of the flexible hinge bodies 645 a can differ from the profile of at least one other of the flexible hinge bodies 645 a.
- the hinge 644 preferably includes a hinge body 645 a , which is similar to the hinge body 545 a described herein; several hinge body embodiments are shown and described in detail elsewhere herein, including hinge body 545 a , hinge body 545 a ′, hinge body 545 a ′′, and hinge body 545 a ′′′ ( FIGS. 17 C- 18 F ).
- flexible hinge body 645 a includes central portion 646 a , side portion 646 b , and side portion 646 c .
- Adhesive 670 a is preferably located between each side portion 646 b , 646 c and the respective rigid panel 636 as illustrated in FIG. 35 A to protect against passage of debris or precipitation into the cargo box 5 ; the adhesive 670 a can also aid in securement of the flexible hinge 644 to the respective rigid panel 636 .
- the adhesive 670 a can include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between the rigid panel 636 and the respective flexible hinge 644 or to secure the flexible hinge 644 to the respective rigid panel 636 .
- the adhesive 670 a includes a double-sided adhesive tape 671 a , which preferably includes an acrylic foam material 672 a , with adhesive layer 672 b arranged on one side of the acrylic foam material 672 a , and adhesive layer 672 c arranged on the other side of the acrylic foam material 672 a , for example.
- the double-sided adhesive tape 671 a can be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”)
- the adhesive layer 672 b includes heat-activated adhesive
- an adhesive layer 672 c includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer 672 c .
- the adhesive layer 672 b (in this example, heat-activated adhesive) is aligned with the flexible hinge body 645 a while the heat-activated adhesive is activated to adhere the double-sided adhesive tape 671 a to the flexible hinge body 645 a ; the flexible hinge body 645 a together with the attached double-sided adhesive tape 671 a is subsequently aligned with the rigid panel 636 and the release strip is removed.
- the adhesive layer 672 c is aligned with the panel 636
- the flexible hinge body 645 a is attached to the rigid panel 636 by activating the adhesive layer 672 c (in this example, pressure-sensitive adhesive).
- the adjacent rigid panel 636 is similarly attached to the flexible hinge body 645 a with double-sided adhesive tape 671 a forming the structure of hinge 644 illustrated in FIG. 35 B .
- the flexible hinge body 645 a allows the hinge 644 to take a flat or open configuration as illustrated in FIGS. 35 A and 35 B , or to flex or bend as illustrated in FIG. 35 C , and other figures herein, providing a flexible hinge 644 that allows the folding cover assembly 630 to fold as illustrated throughout the Figures and described herein, with rigid panels 636 folding up and rotating towards other rigid panels 636 as shown.
- the flexible hinge body 645 a is adhered to the respective bottom or underside 638 of the rigid panels 636 (specifically, the underside 638 a - 638 e off respective adjacent panels of 636 a - 636 ed as described herein) of the folding cover assembly 530 as shown.
- the hinges 44 are securely attached to the respective rigid panels 636 and are sealed to prevent water or debris from entering the cargo box through the folding cover assembly 630 at the hinges 644 , and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which a typical cargo box 5 would be exposed.
- the support bows 650 are also schematically illustrated in FIGS. 35 A- 35 C .
- the support bows 650 are similar to support bows 550 described herein ( FIGS. 16 A- 16 K ) which preferably include a bow main portion 584 including a generally C-shaped channels with a bow upper portion 585 configured for attachment to the bottom surface 538 of the respective panel 536 and oriented with a channel opening 566 c at the bottom.
- the support bows 650 which are located at the flexible hinges 644 preferably include a hinge support flange 686 similar to hinge support flange 586 , 586 a , 586 b ; the support bows which are located at the flexible hinges 644 preferably also include a flange lip similar to flange lip 587 , 587 a , 587 b.
- the support bows 650 are secured to the respective panel 636 .
- the support bows 650 are preferably located at the bottom surface 638 of the respective panel 636 , and near the front edge 641 b or rear edge 641 c of the respective panel 636 .
- the support bows 650 are preferably secured to the bottom surface 638 of the respective panel 636 by an adhesive 670 b , which may include a layer or coating of adhesive or a double-sided adhesive tape 671 b , for example.
- an adhesive 670 b which may include a layer or coating of adhesive or a double-sided adhesive tape 671 b , for example.
- a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination can be used to attach the support bows 650 , to the respective panels 636 .
- the double-sided adhesive tape 671 b preferably includes an acrylic foam material 672 d with adhesive layer 672 e arranged on one side of the acrylic foam material 672 d and adhesive layer 672 f arranged on the other side of the acrylic foam material 672 d , for example.
- the adhesive 670 b includes a double-sided adhesive tape 671 b such as 3M CV62F from 3M, St. Paul, Minn.
- the double-sided adhesive tape 671 b is an acrylic foam tape having an adhesive layer 672 e which includes pressure-sensitive adhesive and having an adhesive layer 672 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 672 f .
- the adhesive layer 672 e in this example, pressure-sensitive adhesive
- the adhesive layer 672 e is aligned with and adhered to the upper surface 666 d of the support bow 650 to adhere the double-sided adhesive tape 671 b to the support bow 650 ; the support bow 650 together with the attached double-sided adhesive tape 671 b is subsequently aligned with the panel 636 and the release strip is removed.
- the adhesive layer 672 f is then aligned with the panel 636 and the support bow 650 is attached to the respective panel 636 by activating the adhesive layer 672 f (in this example, pressure-sensitive adhesive).
- the adhesive layer 672 f in this example, pressure-sensitive adhesive
- any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material 672 a , 672 d is also preferable but not always required.
- a single layer of adhesive could be used, similar to the arrangement schematically illustrated in FIG. 35 A .
- Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J.
- the sidebars or handles 659 are preferably also attached to the bottom surface or underside 638 of the respective panels 636 , preferably in a similar manner as that just described for the support bow 650 .
- adhesive 670 b can be applied at selected portions of the length of the support bow 650 or the sidebar 659
- adhesive 670 b is preferably applied along substantially the entire length of the support bow 650 and the sidebar 659 , to enhance stability and to minimize unwanted vibrations.
- the sidebars 659 and support bows 650 can be attached to the panels 636 with adhesives such as glue, or with fasteners, or spot welds.
- the folding cover assembly 630 folds in stages or steps; a preferred embodiment is schematically illustrated in FIG. 35 D .
- the hinge 544 a flexes to allow the rear panel 636 a to fold up, passing through 90 degrees (configuration 2 ) towards the middle panel 636 b , and fold over onto the middle panel 636 b (configuration 3 ).
- the hinge 644 b flexes to allow the middle panel 636 b (together with the rear panel 636 a which is folded onto the middle panel 636 b ) to fold up, passing through 90 degrees (configuration 4 ) towards the spacer panel 636 d , passing through a point at which standoffs 658 contact the front panel (configuration 5 ).
- the hinge 644 b flexes back towards 90 degrees as the hinge 644 c flexes to allow the spacer panel 636 d to fold up, and continue to fold over (together with the rear panel 636 a which is folded onto the middle panel 636 b , and the middle panel 636 b ) towards the front panel 636 c (configuration 6 ), until the folding cover assembly 30 is folded up onto the front panel 636 c (configuration 7 ).
- the hinge 644 d flexes to allow the front panel 636 c (together with the rear panel 636 a , middle panel 636 b , and spacer panel 636 d ) to a generally vertical orientation onto the cab panel 636 e (configuration 8 ).
- FIG. 35 D is a schematic overview of the general folding of the folding cover assembly 630 ; the various configurations are further illustrated and described elsewhere herein in greater detail.
- the rear end of the rear panel 636 a can be lifted up from both side rails 620 a and 620 b , bending the hinge 644 a as illustrated in FIGS. 36 A and 36 B .
- the engaging portion 653 b of the latch slide 653 of latch 652 c is engaged with the side rail 620 a to restrict the middle panel 636 b from being lifted up from the cargo box 5 .
- the rear panel 636 a is rotated further, onto the middle panel 636 b as illustrated in FIGS. 37 A and 37 B .
- the engaging portion 653 b of latch slide 653 of the latch 652 c is engaged with the side rail 620 a to restrict the middle panel 636 b from being lifted up from the cargo box 5 .
- the release cord 654 b can be pulled, which will retract each of the latches 652 c and 652 d against the force of the respective biasing member or spring 656 , as shown in FIG.
- FIGS. 37 B- 37 C The driver's side portion of the support bow 650 c is shown in FIGS. 37 B- 37 C ; the other end of the support bow 650 c (toward the passenger side) has a mirror-image configuration, and when the release cord 654 b is pulled, the latches 652 at both ends of the support bow 650 c are retracted, so that the rear end of the middle panel 636 b , together with the rear panel 636 a , can be lifted up from both side rails 620 a and 620 b.
- FIG. 37 C Once the latches 652 at both ends of the support bow 650 b are retracted as shown in FIG. 37 C and described above, the rear end of the middle panel 636 b can be lifted up from both side rails 620 a and 620 b , bending the hinge 644 b as illustrated in FIGS. 38 A and 38 B .
- FIG. 38 A and 38 B FIG. 38 A
- 38 A shows the configuration in which the rear panel 636 a is folded over onto the middle panel 636 b and wherein both the rear panel 636 a and the middle panel 636 b have been lifted up and pivoted forward generally about 90 degrees with respect to the front panel 636 c that is resting on the side rails 620 a , 620 b and is generally in a horizontal plane with respect to the pickup truck which is shown in part in phantom.
- the hook 662 d is disengaged from the catch 664 d as the middle panel 636 b is lifted up from the cargo box 5 , as shown in FIG. 38 B .
- the folding cover assembly 630 includes 4 standoffs 658 .
- the standoffs 658 are preferably attached to the handles 659 near the front and back of the panel 636 a as shown in FIG. 37 A and elsewhere herein; alternatively, the standoffs 658 can be attached to the bottom surface 638 a of the rear panel 636 a or attached to other structures such as support bows 650 a , 650 b .
- the standoffs 658 are preferably located so that two are proximate the front edge 641 b of the rear panel 636 a , and two are proximate the rear edge 641 c of the rear panel 636 a .
- the standoffs 658 proximate the rear edge 641 c of the rear panel 636 a contact the top surface 637 c of the front panel 636 c and help to maintain a spaced relationship between the rear panel 636 a and the front panel 636 c .
- the hinge 644 c bends and the spacer panel 636 d lifts off the side rails 620 a and 620 b , and the middle panel 636 b , the rear panel 636 a , and the spacer panel 636 d rotate progressively farther frontwards towards the front panel 636 c until the standoffs 658 all contact the front panel 636 c ( FIG. 39 A ).
- the hinges 644 b and 644 c flex as the middle panel 636 b , the rear panel 636 a , and the spacer panel 636 d rotate towards the front panel 636 c .
- the configurations as the folding cover assembly 630 is folded up in this manner are similar to those illustrated for folding up of the folding cover assembly 530 in FIGS. 8 A- 9 A .
- the folding cover assembly 630 is folded onto the front panel 636 c , the rear panel 636 a , middle panel 636 b , front panel 636 c , and cab panel 636 e are approximately parallel to each other, and preferably oriented about horizontally, provided the cargo box 5 and side rails 620 a , 620 b are oriented horizontally; in this configuration, the spacer panel 636 d is preferably oriented approximately vertically, although it can be somewhat off vertical as illustrated in FIGS. 5 E and 5 F for alternate folding cover assemblies 530 ′ and 530 ′′.
- the folding cover assembly 630 is folded up, but is still “flat” on the cargo box 5 and still attached to the side rails 620 a and 620 b , with the latches 652 e and 652 f (proximate the ends of the support bow 650 f ) engaged with the side rail lip 624 of the side rails 620 a and 620 b , respectively, as illustrated in FIGS. 39 A- 39 B .
- the latches 652 e and 652 f proximate the ends of the support bow 650 f
- FIG. 39 B a portion of the driver's side of the partially folded folding cover assembly 630 is illustrated, showing the engaging portion 653 of the latch 652 e near the driver's-side end portion of the support bow 650 f engaged with the lip 624 of the driver's side side rail 620 a and the containment bracket 625 a .
- the link 681 attached to tether 680 is shown detached from the side rail 620 a for illustration.
- the release cord 654 c can be pulled, which will retract each of the latches 652 e and 652 f against the force of the respective biasing member or spring 656 , as shown in FIG. 39 C , releasing the latches 652 from the side rails 620 a and 620 b and allowing the rear portion of the front panel 636 a to be lifted up from the side rails 620 a and 620 b .
- the link 681 attached to tether 680 is shown attached from the side rail 620 a.
- FIG. 39 D shows a portion of the folding tonneau cover apparatus 610 in the configuration illustrated in FIGS. 39 A- 39 B , but seen from the line 39 D,E- 39 D,E of FIG. 39 A illustrating the driver's side of the partially folded tonneau cover assembly.
- the storage strap 643 d is seen, not secured to the storage retainer 643 e .
- a standoff 658 is also shown.
- the storage strap 643 d can be pulled down and secured to the storage retainer 643 e as shown in FIG. 39 D (by engaging the storage strap 643 d with the retainer hook 643 f shown in FIG. 32 G ).
- the operator 8 can lift up the rear panel 636 a , middle panel 636 b , front panel 636 c and spacer panel 636 d onto the cab panel 636 e , disengage the two cab braces 668 a from the cab brace retainers 668 f ( FIG. 40 C ), pivot the cab braces 668 a forward and secure the cab braces 668 a to the cab bracket assemblies 667 c to secure the folded-up folding cover assembly 630 in a generally vertical orientation adjacent the cab 4 as illustrated in FIG. 40 .
- the operator 8 can attach or detach the cab braces 668 a from the cab bracket assemblies 667 c , or actuate the retainer hex bolts 678 a or retainer handle bolts 678 b to disengage the folding cover assembly 630 from the side rails 620 a , 620 b to remove the folding cover assembly 630 from the support frame assembly 618 or attach the folding cover assembly 630 to the support frame assembly 618 as desired.
- the folding cover assembly 630 is further illustrated in a folded-up vertical configuration in FIG. 40 A , which shows the rear panel 636 a , middle panel 636 b , front panel 636 c and spacer panel 636 d rotated onto the cab panel 636 e and engaged with the retainer nest 643 g of each of the storage retainers 643 e , and the standoffs 658 maintaining the separation of the rear panel 636 a and the front panel 636 c .
- the tether 680 is secured by attaching the link 681 to the aperture 683 in the side rail 620 a .
- each cab brace 668 a is secured to the support bow 650 e by a cab brace retainer 668 f .
- FIG. 40 C A detailed view of a portion of the folding cover assembly 630 is illustrated in FIG. 40 C , which shows one of the cab braces 668 a secured to the support bow 650 e which is secured to the bottom surface 638 d of the spacer panel 636 d .
- the cab brace 668 a is secured to the support bow 650 e by the cab brace fastener assembly 668 d and by the cab brace retainer 668 f .
- the cab brace second end portion 668 c is also shown.
- FIG. 40 D is a similar view as FIG. 40 C , but shows the cab brace disengaged from the cab brace retainer 668 f .
- the cab brace first end portion 668 g and cab brace first end portion top surface 668 i , the cab brace body portion 668 b and cab brace body portion top surface 668 h , and the cab brace second end portion 668 c and cab brace second end portion top surface 668 j are also shown.
- the support bow 650 e of the folding cover assembly 630 when in a generally vertical configuration such as that illustrated in FIG. 40 B , will be at a similar height or somewhat higher than the cab 4 .
- the cab brace second end portion 668 c is preferably bent upward at a cab brace angle 668 e that is preferably between about 1 degree to about 16 degrees, so that the cab brace second portion 668 c engages the anchor post 667 f ( FIG. 40 G ) perpendicularly.
- the cab brace angle 668 e ′ is about 5 degrees; in another example, the cab brace angle 668 e ′′ is about 15 degrees.
- the cab brace second end portion 668 c is preferably adapted to secure to the cab bracket assembly 667 c .
- the second end portion 668 c includes a material which can be attracted by a magnet, such as a steel material, and the cab bracket assembly 667 c includes a cab bracket magnet 667 to aid in retaining the cab brace 668 a securely to the cab bracket assembly 667 c .
- a preferred material for the cab brace 668 a is ASTM A36 pickled and oiled hot-rolled steel, preferably about 0.125 inch thick.
- the cab brace 668 a is preferably secured to an auxiliary support bow 650 j which is secured to the bottom surface 638 b of the middle panel 636 b .
- the auxiliary support bow 650 j is preferably oriented so that the cab brace is secured below the auxiliary support bow 650 j as illustrated.
- the auxiliary support bow 650 j is preferably secured to the bottom surface 638 b of the middle panel 636 b by double-sided adhesive tape 671 b , although other adhesive 670 b such as described herein can be utilized.
- the auxiliary support bow 650 j is secured to the middle panel 636 b at a desired location so that the cab brace angle 668 is less than about 16 degrees.
- the cab brace second end portion 668 c is co-planar with the cab brace body portion 668 b , and the cab brace angle 668 e is zero.
- the cab bracket assembly 667 c is further illustrated in FIGS. 40 F- 40 H .
- the cab bracket assembly 667 c preferably includes a cab bracket body 667 d , which includes a cab bracket protrusion or 667 f .
- the cab bracket assembly 667 c preferably includes a cab bracket magnet 667 e that is secured to the cab bracket body 667 d by a cab magnet retainer 667 h .
- the cab bracket assembly 667 c is preferably secured to the cab 4 by cab bracket adhesive 667 j .
- the cab bracket adhesive 667 j is preferably an adhesive foam tape such as Tesa 7078 acrylic foam tape. Other adhesive such as double-sided adhesive tape 671 b or other adhesives such as those described herein can be utilized.
- FIGS. 41 - 48 Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated in FIGS. 41 - 48 .
- a rear perspective view of the folding tonneau cover apparatus or hinged tonneau cover apparatus 710 is illustrated in FIG. 41 , which includes a support frame assembly 718 , and a folding cover assembly or hinged cover assembly 730 incorporating a cab panel 736 e from which a rear panel 736 a can fold, illustrated with the folding or hinged tonneau cover apparatus 710 attached to a pickup truck 2 which is shown in phantom, with a cab 4 , a drivers side 3 a , a passenger side 3 b , a front 3 c , and a rear 3 d .
- the folding tonneau cover apparatus 710 is secured to the truck 2 to cover a cargo box 5 having a drivers side sidewall 6 a , a passenger side sidewall 6 b , a front wall 6 c ( FIG. 48 ), and a tailgate 6 d , which define a top opening 6 f ( FIG. 48 ), a cargo box length 7 a , and a cargo box width 7 b .
- the panels 736 are secured to side rails 720 a , 720 b by latches 752 , latches 752 a and 752 b being partially shown on FIG. 41 .
- the folding cover assembly 730 has a top 732 a and a bottom 732 b.
- FIG. 42 A A top plan view of the folding cover assembly 730 is illustrated in FIG. 42 A , which shows the panels 636 , namely the rear panel 736 a and the cab panel 736 e , each having a top surface 737 a , 737 e , and a width 740 , namely 740 a , 740 e , and a length 739 , namely 739 a , 739 e , respectively; the folding cover assembly 730 has a length 733 and a top 732 a .
- the folding cover assembly 730 preferably includes storage retainers 743 e attached to the cab panel 736 e.
- FIG. 42 B A bottom plan view of the folding tonneau cover apparatus 710 is illustrated in FIG. 42 B , which shows the folding cover assembly 730 , the bottom surfaces 738 a , 738 e of rear panel 736 a and cab panel 736 e , respectively, and support bows 750 , including support bow 750 a (rear of rear panel 736 a ), support bow 750 b (front of rear panel 736 a ), support bow 750 h (cab panel 736 e ), and intermediate support bow(s) 750 spaced along the rear panel 736 a between support bow 750 a and support bow 750 b .
- Handles 759 are attached to the bottom surface 738 of rear panel 736 a , preferably by adhesive 770 b (similar to adhesive 670 b illustrated on FIG. 35 A ) or other adhesive elements such as are described herein.
- adhesive 770 b is double-sided adhesive tape 771 b ( FIG. 35 C ).
- Handles 759 are preferably attached to the bottom surface 738 a of the rear panel 736 a as shown; the standoffs 758 are preferably attached in a similar manner as the attachment of standoffs 558 to support bows 550 as illustrated in FIGS. 14 A- 14 C .
- the folding tonneau cover apparatus 710 also preferably includes a drivers side support beam 773 a and a passenger side support beam 773 b which are secured to the handles 759 to provide additional structural support to the rear panel 736 a .
- the folding tonneau cover apparatus 710 also preferably includes two lift supports or gas struts 774 , with a gas strut 774 secured by a gas strut support beam fastener assembly 775 a to the drivers side support beam 773 a and by a gas strut side rail fastener assembly 775 b to the drivers side side rail 720 a , and a gas strut 774 secured by a gas strut support beam fastener assembly 775 a to the drivers side support beam 773 a and by a gas strut side rail fastener assembly 775 b to the drivers side side rail 720 .
- the folding cover assembly 730 preferably includes snap clips 776 for securing the gas struts 774 to the support beams 773 a , 773 b when the folding cover assembly 730 is not attached to the truck 2 .
- the folding cover assembly 730 preferably includes perimeter seal 734 located at the perimeter of the folding cover assembly 730 ; various configurations of perimeter seal are envisioned, such as the perimeter seals 534 , 534 a - 534 k shown in FIGS. 15 A- 15 H .
- the cab panel 736 e is secured to the side rails 720 a , 720 b by cab panel retainers 779 ( FIG. 42 D ) and retainer bolt 778 ; two retainer bolts are illustrated as examples, including handle bolt 778 b and hex bolt 778 a ( FIG. 421 ).
- the cab panel retainers 779 are also engaged with containment brackets or swing containment brackets 725 c , 725 d which aid in maintaining the position of the folding cover assembly 730 with respect to the side rails 720 a , 720 b and the cargo box 5 .
- the folding tonneau cover apparatus 730 includes hooks 762 a , 762 b which secure to catches 764 a , 764 b .
- the folding tonneau cover apparatus 730 includes hinge supports or hinge support mechanisms 749 ( FIG. 42 I) described herein.
- the folding cover assembly 730 preferably includes a pull-down strap assembly 729 ( FIG. 42 H ) including a strap retainer 729 b and a pull-down strap 729 a ( FIG. 48 ).
- FIG. 42 C A side view of portions of the folding tonneau cover apparatus 710 is illustrated in FIG. 42 C , as viewed from line 42 C- 42 C of FIG. 42 A , and give further understanding of the relative positioning of the elements. Further detailed views of the folding tonneau cover apparatus 710 are illustrated in FIGS. 42 D- 42 G .
- FIG. 42 D shows a portion of the folding tonneau cover apparatus 710 encircled by line 42 D- 42 D on FIG. 42 C , illustrating the cab panel 736 e , the rear portion of the rear panel 736 a , the support bow 750 b mostly obscured by bow end cap 765 , the support bow 750 h , hinge 744 d , hook 762 e , catch 764 e ( FIG.
- swing containment bracket 725 c which keeps latch cab panel retainer 779 in position on the side rail 720 a and helps to maintain the folding cover assembly 730 at the desired location to cover the cargo box 5 .
- the cab panel retainer 779 is secured to the support bow 750 h by handle bolt 778 b.
- FIG. 42 E A bottom perspective view of the folding tonneau cover apparatus 710 is illustrated in FIG. 42 E , with a detail view of the portion of the folding tonneau cover apparatus 710 encircled by line 42 F on FIG. 42 E being illustrated in FIG. 42 F .
- the hinge 744 d , swing containment bracket 725 d , cab panel retainer 779 , handle bolt 778 b , passenger side support beam 773 b , and beam end cap 773 c are also shown.
- a portion of the driver's side of the hinged tonneau cover apparatus 710 is illustrated in a partial section view as seen from the line 42 G- 42 G of FIG. 42 A in FIG. 42 G , which shows the side support beam 773 b secured to handle 759 by adhesive 770 b .
- the support bow 750 b is in place on the side rail lip 724 of side rail 720 a , and perimeter seal 734 seals against the side rail 720 a and the side wall cap 6 e on the drivers side sidewall 6 a .
- the side rail 720 a is secured to the sidewall 6 a by a clamp 714 , which preferably includes the an outer member 716 a , an inner member 716 b , a clamp engagement portion 716 c , and a fastener assembly 716 d ; the fastener assembly can, for example, include a bolt 716 e , a washer 716 f and a nut 716 g as illustrated.
- inner member 716 b has a clamp engagement portion 716 c which, together with side rail engagement portion 722 a of side rail 720 a , aids in securing the clamps 714 in place on the side rail 720 a .
- the clamps 714 are arranged and tightened to secure the side rail 720 a to the sidewall 6 a , with a sidewall gasket 722 c arranged between the side rail 720 a and the sidewall 6 a as illustrated.
- the cab panel retainer 779 and handle bolt are also shown.
- FIG. 42 H An alternate folding tonneau cover apparatus 710 is shown in FIG. 42 H .
- the folding cover assembly 730 includes retainer bolts 778 which are hex bolts 778 a .
- This embodiment also includes hinge supports or hinge support mechanisms 749 ( FIG. 42 I) described herein.
- the folding cover assembly 730 preferably also includes a pull-down strap assembly 729 including a strap retainer 729 b and a pull-down strap 729 a ( FIG. 48 ). Further details are illustrated in FIG. 42 I , which illustrates the front passenger portion of the folding tonneau cover apparatus 710 of FIG. 42 H , similar to the view of FIG. 42 F .
- a hinge support mechanism 749 is shown, as will be more fully described in reference to FIGS. 45 - 47 .
- the folding cover assembly 730 includes a pair of hinge support mechanisms 749 located apart from each other such as illustrated on FIG. 42 H .
- FIG. 42 H The hinged or folding cover assembly 740 of FIG. 42 H is further illustrated in a rear perspective view in Fig., with the folding tonneau cover apparatus 730 attached to a pickup truck 2 which is shown partially and in phantom.
- a partial section view as seen from the line 43 B- 43 B of FIG. 43 A is shown in FIG. 43 B , which shows the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail, and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom.
- the latch 752 a includes latch slide 753 having an engaging portion 753 b which extends forward to engage the lip 724 of the side rail 720 a , so as to secure the panel 730 a to the side rail 720 a .
- the latch slide 753 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used.
- the latch slide 753 includes fiberglass-reinforced nylon.
- the latch slide 753 is biased by a biasing member or spring 756 towards the side rail 720 a so that the engaging portion 753 b engages the side rail 720 a to form a secured configuration in which the rear panel 736 a is restricted from being lifted up from the cargo box 5 ;
- the spring 756 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias the latch slide 753 towards the side rail 720 a so that the engaging portion 753 b engages the side rail 720 a so that the latch 752 a is in the secured configuration.
- the spring 756 is held between the latch slide 753 and a spring retainer assembly 757 .
- the spring retainer assembly 757 is secured in the desired location in the support bow 750 a .
- the side rails 720 a and 720 b preferably include extruded metal, and have a side rail engagement portion 722 a ( FIG. 44 B ), arranged to approximate a portion of the sidewall 6 a , 6 b of the pickup truck 2 .
- the clamp 714 is shown in detail in FIG. 43 B .
- the clamps 714 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.
- Clamps 714 preferably have an outer member 716 a and an inner member 716 b which are tightened towards each other and held as an assembly on the sidewall 6 a by a fastener assembly 716 d which preferably includes a bolt 716 e , a washer 716 f , and a nut 716 g .
- inner member 716 b has a clamp engagement portion 716 c which, together with side rail engagement portion 722 a of side rail 720 a , aids in securing the clamps 714 in place on the side rail 720 a .
- the clamps 714 are arranged and tightened to secure the side rail 720 a to the sidewall 6 a , with a sidewall gasket 722 c arranged between the side rail 720 a and the sidewall 6 a as illustrated.
- a bow end cap 765 is located at the end of the support bow 750 a .
- a release cord 754 and a cord guide 755 a are shown.
- the driver's side portion of the support bow 750 a is shown in FIG. 43 B ; the other end of the support bow 750 a (toward the passenger side) has a mirror-image configuration, with latch 752 b engaging side rail 720 b , and side rail 720 b being attached to sidewall 6 b in a similar manner.
- the release cord 754 a can be pulled, which will retract each of the latches 752 against the force of the respective biasing member or spring 756 .
- the release cord 754 a will be pulled by an operator 8 who has walked to the rear of the cargo box 5 and has opened the tailgate 6 d and reaches in to access and pull the release cord 754 a .
- the engaging portion 753 b of the latch 752 a is retracted away from the lip 724 of the side rail 720 a as shown in FIG.
- the cord guides 755 a adjacent to the latches 752 help to maintain alignment of the ends of the release cord 754 a so that the latches 752 are retracted in alignment with the support bow 750 a , to avoid excessive friction, wear and potential binding.
- the driver's side portion of the support bow 750 a is shown in FIG.
- the other end of the support bow 750 a (toward the passenger side) has a mirror-image configuration, and when the release cord 754 a is pulled, the latches 752 at both ends of the support bow 750 a are retracted, so that the rear end of the rear panel 736 a can be lifted up from both side rails 720 a and 720 b .
- the release cord 754 a is depicted as being pulled in two location; typically the operator 8 would pull the release cord 754 a in only one location, causing both latches to release.
- FIG. 45 illustrates a portion of the hinged cover assembly 730 similar to the portion shown in FIG. 42 I , except that the cover assembly is flipped upside down and the drivers side of the folding cover assembly 730 is shown (which is a mirror image of the passenger side of the folding cover assembly 730 ) and some parts have been removed to reveal underlying structures including the hinge support mechanism 749 , and the rear panel 736 a has been lifted up and is shown in a pivoted orientation with respect to the cab panel 736 e .
- FIGS. 45 - 47 further illustrate the hinge support mechanism 749 . As shown and described herein (see FIG.
- hinge support mechanisms 749 that help to support and stabilize the folding cover assembly 730 , and the rear panel 736 a , and the hinge 744 d as the rear panel 736 a is lifted up and the hinge 744 d is bent, when the rear panel 736 a pivots with respect to the cab panel 736 e .
- the rear panel 736 a can be lifted up and rotated forward around a pivot arc Dl.
- the rear panel 736 a pivots with respect to the cab panel 736 e and generally rotates around a hinge pivot axis 749 h.
- the structure of the hinge 744 d , support bows 750 b , 750 h , and hinge support mechanisms 749 are generally symmetric with respect to the hinge pivot axis 749 h .
- the support bow 750 b preferably includes a hinge support flange 786 extending to support the hinge body 745 a and is located adjacent the front edge 741 b of the rear panel 736 a in a configuration that is a mirror image of the configuration of support bow 750 h located adjacent the rear edge 741 c of the cab panel 736 e as shown (see also FIGS. 35 A- 35 C ).
- each hinge support mechanism 749 includes a hinge bracket 749 a and a hinge bracket 749 b , and a bracket guide pin 749 c which is retained in bracket slots 749 d in each of the hinge brackets 749 a , 749 b .
- Each hinge bracket 749 a , 749 b includes a bracket block 749 e which protrudes from the respective hinge bracket 749 a , 749 b and provides for securement of each hinge bracket 749 a , 749 b to the respective support bow 750 b , 750 h , by a bracket block nut 749 f and a bracket block bolt 749 g .
- the bracket slots 749 d are each curved in a circular arc, and when the hinge brackets 749 a , 749 b and bracket guide pin 749 c are assembled and the hinge brackets 749 a , 749 b are secured to the support bows 750 b , 750 h , the bracket slots 749 d are each curved in a circular arc centered on the hinge pivot axis 749 h , so that when the rear panel 736 a is lifted up and the flexible hinge 744 d bends and the rear panel 736 a rotates around the hinge pivot axis 749 h , the hinge brackets 749 a , 749 b help to constrain the rotation and restrict the pivoting of the rear panel 736 a with respect to the cab panel 736 e and support the rear panel 736 a so that stress on the hinge 744 d is reduced.
- the hinge support mechanisms 749 help to support the front portion of the rear panel 736 a when the rear portion of the rear panel 736 a is lifted up off the side rails 720 a , 720 b , and help to maintain alignment of the rear panel 736 a with respect to the cab panel 636 e , minimizing any relative displacement or skewing, and reducing stress on the hinge 744 d .
- the hinge pivot axis 749 h is generally parallel to the hinge longitudinal axis 745 b (see hinge longitudinal axis 545 b on FIG. 17 C ) and may be within or proximate to the hinge body 745 c .
- a perspective view of portions of the hinge support mechanism 749 is shown in FIG. 47 to better show the detailed structure.
- the hinge 744 d preferably includes adhesive such as double-sided adhesive tape 771 c to seal the ends of the hinge body 745 a against the perimeter seal 734 to prevent precipitation or debris entry into the cargo box 5 past the hinge 744 d .
- adhesive such as double-sided adhesive tape 771 c to seal the ends of the hinge body 745 a against the perimeter seal 734 to prevent precipitation or debris entry into the cargo box 5 past the hinge 744 d .
- a short piece of double-sided adhesive tape 771 c such as about 1 ⁇ 4 inch by 5 ⁇ 8 inch is adhered at each end; suitable material includes an adhesive foam tape such as Tesa 7078 acrylic foam tape.
- Other hinges disclosed herein, including hinges 444 , 544 , 644 can incorporate such double-sided adhesive tape to similarly provide a weather seal at each end of the respective hinge.
- the latches 752 a , 752 b will engage the side rail lip 724 of each of the side rails 720 a , 720 b and secure the folding cover assembly 730 to the side rails 720 a , 720 b.
Abstract
A tonneau cover apparatus for removable attachment to a cargo box of a pickup truck including a support frame assembly and a cover assembly. The cover assembly includes a plurality of pivotally interconnected rigid panels that can be folded up and secured to the cargo box such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation. The tonneau cover apparatus further includes a mechanism for securing the at least two of the plurality of rigid panels in the upright folded orientation. A method of removably securing the tonneau cover apparatus to the pickup truck is also described, as is an alternate embodiment of the tonneau cover apparatus, wherein the cover assembly includes first and second pivotally interconnected rigid panels and a pair of hinge support mechanisms that generally restrict the way the second rigid panel pivots.
Description
- This application is a continuation of U.S. application Ser. No. 17/089,611, filed on Nov. 4, 2020, which is a continuation in-part of U.S. application Ser. No. 16/252,345, filed on Jan. 18, 2019, which is a continuation of U.S. application Ser. No. 15/794,549, filed on Oct. 26, 2017, now U.S. Pat. No. 10,189,340, which claims the benefit of U.S. Provisional Application No. 62/414,591, filed on Oct. 28, 2016; this application is also a continuation-in-part of U.S. application Ser. No. 16/865,132, filed on May 1, 2020, which claims the benefit of U.S. Provisional Application No. 62/845,086, filed on May 8, 2019, and U.S. Provisional Application No. 62/843,357, filed on May 3, 2019, which applications are incorporated herein by reference in their entirety.
- A tonneau cover apparatus for covering an open bed or cargo box of a pickup truck. The tonneau cover apparatus preferably including a folding cover assembly having a plurality of rigid panels that are interconnected in series by a series of hinges in such a manner that the respective panels can pivot with respect to one another, so as to fold up while the cover assembly is secured to a support frame assembly, when the support frame assembly is secured to the cargo box of the pickup truck. In preferred embodiments a plurality of the rigid panels can be secured in an upright folded orientation when the cover assembly is detachably secured to the pickup truck. Alternately, a tonneau cover apparatus is provided that preferably includes two rigid panels, a cab panel that can be secured to a support frame assembly that is secured to a cargo box of a pickup truck and a lift-up panel that is pivotally interconnected in series with the cab panel when the cab panel is secured to the support frame assembly. The lift-up panel is interconnected to the cab panel by a hinge, preferably a flexible hinge, and the cover assembly includes two hinge support mechanism, each having opposing first and second hinge brackets secured to a lower surface of the cab panel and the lift-up panel, respectively, in such a manner that the respective panels can pivot with respect to one another with the guidance of the opposing guide brackets. Methods of covering a cargo box of a pickup truck are also provided.
- Numerous protective cover assemblies for preventing rain, debris and wind from damaging or disrupting the contents of a pickup truck bed or cargo box are currently available. Among these protective cover assemblies are tonneau covers. Some tonneau covers are made of a fabric material, often a fabric coated with a polymeric material, which is fastened to a rigid frame so as to enclose and protect the pickup truck cargo box. Various covering materials are used for such tonneau covers; some are flexible and/or stretchable, and others are more rigid, and they are secured to the pickup truck in various manners to cover the cargo box. Tonneau covers are opened in various manners to allow entry into the cargo box, such as by rolling the cover up, folding the cover up, lifting a hard cover upward or pivoting the cover upward, or disconnecting and removing the cover from the cargo box altogether, in some cases after the cover assembly is folded up.
- Typical tonneau covers have support frames including a pair of elongated side rails that are secured to the sidewalls of the cargo box of the pickup truck. Known tonneau covers are often secured to the side rails using hook and loop strip fastener components secured to the side rail, typically within a horizontal channel (see, e.g., U.S. Pat. Nos. 4,036,521; 4,991,640; 6,752,449 and U.S. Patent Application Pub. No. 2004/0212212 A1). Some tonneau covers are secured to the side rails by latches (see. e.g., U.S. Pat. No. 7,104,586). Some tonneau covers include rigid panels which are folded up for cargo access (see e.g., U.S. Pat. No. 10,189,340). While there are many, many tonneau covers, too many to review them all in this space, the present inventions provide improvements that address limitations associated with the prior art.
- The present invention preferably includes a tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position. The tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly preferably including a plurality of rigid panels. In preferred embodiments the cover assembly includes a flexible hinge; wherein the plurality of rigid panels, including first and second rigid panels which are pivotally secured to one another by a hinge, preferably the flexible hinge.
- In a preferred embodiment, the cover assembly includes a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another. The tonneau cover apparatus preferably further includes a mechanism for securing the respective upper surfaces of the at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the pickup truck, preferably a cab positioned forward of the cargo box and a securing member attached to the cover assembly, wherein the securing member can engage the bracket so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation. In preferred embodiments, the securing member and the bracket are magnetically attracted to one another and the bracket will preferably contain a magnet. In further preferred embodiments, the securing member is made of steel and is magnetically attracted to the magnet contained in the bracket and the bracket is adhesively secured to the cab. The securing member is preferably an elongated rigid member that has first and second ends and the elongated rigid member is bent in such a way that first and second upper surfaces of the respective first and second ends of the elongated rigid member are oriented at an angle to one another of from about 1 degree to about 16 degrees.
- A method of removably securing the tonneau cover apparatus to the pickup truck is also provided. The method preferably including the steps of providing a support frame assembly for attachment to the cargo box; a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the plurality of rigid panels include first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the at least two of the plurality of rigid panels reside in a generally parallel orientation to one another; and 3) a mechanism for securing the respective upper surfaces of at least two of the plurality of rigid panels in the upright folded orientation; said mechanism for securing including a bracket secured to a portion of the cab and a securing member attached to the cover assembly, wherein the securing member can engage the bracket when the bracket is secured to the cab so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation; wherein the securing member and the bracket are magnetically attracted to one another; and securing the support frame to the pickup truck; securing the cover assembly to the support frame and the bracket to the cab; positioning the cover assembly so that the cover assembly is folded up when the cover assembly is secured to the support frame, such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation; and engaging the securing member to the bracket so as to secure the cover assembly to the cab when the at least two of the plurality of rigid panels reside in the upright folded orientation.
- In a further embodiment of the present invention, a tonneau cover apparatus is provided for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of a cargo box including a forward end, two opposing sidewalls and a tailgate; the tailgate being positioned rearward of the forward end and having an open position and a closed position. The tonneau cover apparatus preferably includes a support frame assembly for attachment to the cargo box; and a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box. The cover assembly preferably having a plurality of rigid panels including first and second rigid panels that are pivotally interconnected with one another by a hinge; wherein each of the respective rigid panels have an upper surface and a lower surface; and wherein the first rigid panel can be secured to the support frame assembly when the support frame assembly is secured to the pickup truck; wherein the cover assembly further includes a pair of hinge support mechanisms that generally restrict the way in which the second rigid panel pivots with respect to the first rigid panel; wherein each of the hinge support mechanisms include opposing first and second hinge support brackets secured to the lower surfaces of the first and second rigid panels, respectively, proximate the hinge so that the opposing first and second hinge support brackets of each of the respective hinge support mechanisms are slideably engaged with one another when the first and second rigid panels pivot with respect to one another. In preferred embodiments, each of the respective opposing hinge support brackets include a guide pin and an arcuate guide slot; and wherein, when the support frame assembly is attached to the cargo box, the cover assembly is attached to the support frame assembly, and the second rigid panel pivots with respect to the first rigid panel, the respective guide pins of each of the opposing hinge support brackets slide within the respective arcuate slots of the opposing hinge support brackets.
- These and various other advantages and features of novelty which characterize the present invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described preferred embodiments of the present invention.
- In the drawings, in which corresponding reference numerals and letters indicate corresponding parts of the various embodiments throughout the several views, and in which the various embodiments generally differ only in the manner described and/or shown, but otherwise include parts corresponding to the parts in the previously described embodiment;
-
FIG. 1 is a rear perspective view of a folding tonneau cover apparatus according to the present invention, including a folding cover assembly and a support frame assembly, and shown attached to a pickup truck which is shown in phantom; -
FIG. 2A is a top plan view showing the folding tonneau cover assembly shown inFIG. 1 and also showing aprotective film 574 on the top surface of thefront panel 536 c, that is not shown in subsequent Figures, with the exception ofFIGS. 9A, 10A, and 10 B where the protective film shown is again shown; -
FIG. 2B is a bottom plan view of the folding tonneau cover apparatus ofFIG. 1 ; -
FIG. 2C is a side view of the folding tonneau cover apparatus ofFIG. 1 as viewed fromline 2C-2C ofFIG. 2A which illustrates the driver's side of the pickup truck shown inFIG. 1 ; however, for clarity of illustration, the perimeter seal on the underside of the outer edge of the respective panels is not shown; -
FIG. 2D is a detailed view of a portion of the folding tonneau cover apparatus encircled by thedashed line FIG. 2C , illustrating the rear hinge, with a portion of the driver's-side side rail broken away to show the underlying structure; -
FIG. 2E is a detailed view of a portion of the folding tonneau cover apparatus encircled by dashedline 2E ofFIG. 2C , illustrating the middle hinge and the front hinge, with a portion of the driver's-side side rail broken away to show the underlying structure; -
FIG. 2F is an enlarged detailed top plan view of a portion of the folding tonneau cover apparatus shown in the dashedrectangle 2F ofFIG. 2A , with portions broken away to show the underlying structure and showing the support member in partial cross section and illustrating the engaging portion of the latch engaged with the containment bracket and the side rail, and showing an alternate position of the engaging portion of the latch in phantom when it is retracted from the containment bracket and with other structures shown in phantom to indicate the relative position of the respective elements; -
FIG. 2G is an enlarged perspective view as seen generally from aline 2G-2G ofFIG. 2B which is seen from below of a portion of a folding tonneau cover apparatus similar to the folding tonneau cover apparatus shown inFIG. 2B , except that the side rail shown inFIG. 2G is an alternatepassenger side rail 520 d, which differs from theside rail 520 b shown inFIG. 2B ; -
FIG. 2H is an exploded perspective view of an alternative driver's-side split side rail, that is a mirror image of the passenger side split side rail shown inFIG. 2G , both of which have a plurality of sections which are joined together by a driver's side containment bracket; -
FIG. 3A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 , illustrating additional details; -
FIG. 3B is a partial section view as seen from theline 3B-3B ofFIG. 3A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom; -
FIG. 4A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 , with the release cord pulled to pull the latch against the bias of the spring to release the latch from the engagement with the side rail; -
FIG. 4B is a is a partial section view as seen from theline 4B-4B ofFIG. 4A similar to the view ofFIG. 3B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail; -
FIG. 5A is schematic illustration of a vertical cross section along a front-to-back plane as seen from theline 5A-5A ofFIG. 2A of one of the hinges of the folding tonneau cover assembly ofFIG. 1 showing the basic configuration with the hinge unfolded; -
FIG. 5B is a schematic illustration similar toFIG. 5A of a transverse vertical cross section along a front-to-back plane showing an alternate embodiment of one of the hinges of the folding tonneau cover assembly ofFIG. 1 showing the hinge unfolded; -
FIG. 5C is a schematic illustration showing the hinge ofFIG. 5B , but with the hinge folded at about 45 degrees from the unfolded orientation shown inFIG. 5B ; -
FIG. 5D is a schematic illustration showing the general steps and configurations of the folding tonneau cover assembly ofFIG. 1 as it is folded up into a fully folded orientation; -
FIG. 5E is a further schematic illustration showing an alternate configuration of the fully folded orientation of the tonneau cover assembly ofFIG. 5D ; -
FIG. 5F is a further schematic illustration similar to that ofFIG. 5E , but showing yet another alternate configuration of the fully folded tonneau cover assembly; -
FIG. 6A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 wherein the latches on the rear panel have been released to allow the rear panel to be lifted up in a first step toward folding up the tonneau cover assembly; -
FIG. 6B is a partial section view as seen fromline 6B-6B ofFIG. 6A showing the hook orswing latch 562 a near the driver's side end portion of the rear support bow of the middle panel retracted fromcatch 564 a secured to the lip of the side rail; -
FIG. 7A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 wherein the rear panel has been rotated forward onto the middle panel in a further step toward folding up the cover assembly; -
FIG. 7B is a partial section view as seen from theline 7B-7B ofFIG. 7A showing the engaging portion of theswing latch 562 a disengaged from thecatch 564 a; -
FIG. 7C is a schematic illustration similar to that shown inFIG. 5C showing the alternate hinge body ofFIG. 5B but with the hinge body folded about 180 degrees as shown in the configuration illustrated inFIGS. 7A-7B ; -
FIG. 8A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 , wherein the rear panel is folded over onto the middle panel and wherein both panels have been lifted up and pivoted forward generally about 90 degrees with respect to the front panel that is resting on the side rails and is generally in a horizontal plane with respect to the pickup truck shown in part in phantom; -
FIG. 8B is a partial section view as seen from theline 8B-8B ofFIG. 8A showing theswing latch 562 c near the driver's-side end portion of the support bow of the spacer panel disengaged from thecorresponding catch 564 c; -
FIG. 8C is a side view as seen from theline 8C-8C ofFIG. 8A , but illustrating the rear panel together with the middle panel engaged top surface to top surface as shown inFIG. 8A , but showing the two panels rotated forward further than shown inFIG. 8A to the point that thestandoff 558 touches thefront panel 536 c; -
FIG. 8D is a side view similar toFIG. 8C , except that the rear panel together with the middle panel are rotated further forward so that the standoff is touching the front panel and the spacer panel is lifted up and rotated partially forward; -
FIG. 8E is a side view similar toFIG. 8D , except that the rear panel together with the front panel are rotated still further forward and the standoff is touching the front panel and the spacer panel is lifted up further and rotated further forward; -
FIG. 8F is a schematic illustration showing a transverse vertical cross section similar to that ofFIGS. 5C and 7C , but showing the spacer panel and two adjacent alternate hinges of the folding tonneau cover assembly of the present invention, illustrating both of the alternate hinges in a partially folded configuration similar to the partially folded orientation shown inFIG. 8D ; -
FIG. 9A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 showing the rear panel together with the middle panel and the spacer panel rotated forward so that the middle panel and the rear panel are resting together on the top of the front panel, with the spacer panel rotated upward generally at a 90 degree angle to the other panels in a fully folded orientation, but also showing thestandoffs 558 resting on alternateprotective films 574 shown only inFIGS. 2A, 9A, 10A, and 10B as an alternate element in those figures; -
FIG. 9B is a partial section view as seen from theline 9B-9B ofFIG. 9A illustrating the driver's side of the completely folded tonneau cover assembly showing the rear support bow of the front panel resting on the lip of the driver's side side rail; -
FIG. 10A is a front perspective view of the folding tonneau cover apparatus ofFIG. 1 wherein the rear panel together with the middle panel and the spacer panel have been pivoted or rotated forward so that the middle panel and the rear panel are resting on the top surface of the front panel as inFIG. 9A and showing the alternate protective film on the front panel engaged by thestandoff 558 which rests on theprotective film 574; -
FIG. 10B is a front perspective view of the folding tonneau cover apparatus ofFIG. 1 similar to the view ofFIG. 10A , but showing thestorage strap 543 a pulled down and astrap bracket 543 b engaged with abracket slot 543 c on the front edge of the front panel, securing the foldingtonneau cover assembly 530 in the fully folded up configuration; -
FIG. 10C is a front view of the folding tonneau cover apparatus ofFIG. 1 showing a storage strap toward each side of the folded tonneau cover, with each storage strap pulled down and a strap bracket engaged with a bracket slot on the front edge of the front panel, securing the folding tonneau cover in the folded up configuration; -
FIG. 10D is a side view from the driver's side of the folding tonneau cover apparatus ofFIG. 1 in the configuration ofFIG. 10C further showing the fully folded configuration and schematically illustrating the flexible hinges in the folded-up configuration, with one of the storage straps being visible and a strap bracket engaged with a bracket slot on the front panel, securing the folding tonneau cover in the fully folded up configuration; -
FIG. 10E is a schematic illustration showing a transverse vertical cross section similar to that ofFIG. 8F , showing the a spacer panel and two adjacent hinges of the folding tonneau cover ofFIG. 1 , illustrating both of the alternate hinges in a 90-degree folded configuration; -
FIG. 11A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 1 viewed from slightly below and to the driver's side of the folding tonneau cover apparatus, wherein the folding tonneau cover assembly is secured in the fully folded up configuration similar to that ofFIGS. 10B-10D , showing a release cord for pulling the latches on the front panel against the bias of the springs to release the latches and schematically illustrating the flexible hinges in a manner similar to that inFIG. 10D ; -
FIG. 11B is a partial view of the portion of the folding tonneau cover apparatus ofFIG. 1 shown in the dashedrectangle 11B ofFIG. 11A , illustrating clip cord guides and a retainer cord guide and a corresponding release cord along a support bow, with the support bow shown in phantom to reveal the underlying structures; -
FIG. 12 illustrates the foldingtonneau cover assembly 530 ofFIG. 1 , secured in the fully folded up configuration disengaged from thesupport frame assembly 518 and being held in the arms of an operator; -
FIG. 13A illustrates a clip cord guide aligned for attachment to a support bow or support member; -
FIG. 13B illustrates the clip cord guide ofFIG. 13A inserted into a channel of the support bow; -
FIG. 13C illustrates the clip cord guide ofFIGS. 13A and 13B rotated so that an oblong securement feature engages the clip cord guide within the channel of the support bow; -
FIG. 13D illustrates a retainer cord guide secured to a support bow; -
FIG. 14A is a perspective view illustrating a standoff; -
FIG. 14B is a side view illustrating the standoff ofFIG. 14A withlongitudinal groove 558 b engaged with asidebar 559 secured to the bottom surface of therear panel 536 a and showing the support bow in phantom; -
FIG. 14C is a side view illustrating the standoff ofFIGS. 14A and 14B pivoted upward so that thelongitudinal groove 558 c is engaged with the sidebar as shown and illustrating a standoff distance between a top of the protective pad on the standoff and the top surface of the rear panel and showing the support bow in phantom; -
FIG. 15A illustrates a preferred perimeter seal in a transverse vertical cross section; -
FIG. 15B illustrates an alternate perimeter seal in a transverse vertical cross section; -
FIG. 15C illustrates a further alternate perimeter seal in a transverse vertical cross section; -
FIG. 15D illustrates another alternate perimeter seal in a transverse vertical cross section; -
FIG. 15E illustrates another alternate perimeter seal in a transverse vertical cross section; -
FIG. 15F illustrates a rigid panel edge guard in a transverse vertical cross section; -
FIG. 15G illustrates a still further alternate perimeter seal in a transverse vertical cross section; -
FIG. 15H illustrates a further alternate perimeter seal in a transverse vertical cross section; -
FIG. 16A illustrates a front view of a support bow or support member; -
FIG. 16B illustrates an alternate support bow similar to the support bow ofFIG. 16A , but wherein the alternate support bow has a slight bend or deflection of the support bow making its upper surface curved downwardly at the ends; -
FIG. 16C is an end view of the support bow ofFIG. 16B showing the deflection d; -
FIG. 16D is a schematic illustration of a front view of arigid panel 536′ of the folding tonneau cover ofFIG. 1 ; -
FIG. 16E is a schematic illustration of a rigid panel ofFIG. 16D after being attached to the support bow ofFIG. 16B , causing the panel to have a slight downwardly concave curvature reflecting the deflection of the alternate support bow ofFIG. 16B ; -
FIG. 16F is a perspective view of a straight support bow or support member with no hinge support flange and no downward deflection; -
FIG. 16G is a perspective view of a curved support bow or support member with no hinge support flange and a downward curvature or deflection; -
FIG. 16H is a perspective view of a straight support bow with one hinge support flange having a lip; -
FIG. 16I is a perspective view of a curved support bow having a downward deflection and one hinge support flange having a lip; -
FIG. 16J is a perspective view of a straight support bow having two hinge support flanges; -
FIG. 16K is a perspective view of a curved support bow having two hinge support flanges and a downward deflection; -
FIG. 17A is a cross sectional detail view as seen from theline 17A-17A inFIG. 3A , showing additional details in the vicinity of the side of the spacer panel, and showing two flexible hinges, a latch, a containment bracket, a hook, and a catch; -
FIG. 17B is a cross sectional detail view similar to the view shown inFIG. 17A , but with one of the flexible hinges folded up from the side rail, similar to the configuration ofFIG. 8A ; -
FIG. 17C is a perspective view of a hinge body of the folding cover assembly ofFIG. 1 shown isolated and in an unfolded configuration; -
FIG. 17D is a perspective view of a portion of the hinge body including a transverse vertical cross sectional view of the hinge body taken from the dashedrectangle 17D shown inFIG. 17C ; -
FIG. 17E is a view that is similar to the view shown inFIG. 17D , except that the hinge body that is shown is an alternate hinge body; -
FIG. 17F is a view that is similar to the view shown inFIG. 17D , except that the hinge body that is shown is an alternate hinge body; -
FIG. 17G is an enlarged schematic illustration similar to that shown inFIG. 18J , which is referenced herein below, except that the hinge body is different which allows the configuration of thepartial enclosure 592 to engage thealternate hinge body 545 a′″ in a slightly different manner wherein the panel 336 does not abut against thehinge body 545 a′″ the same way that is shown inFIG. 18J ; -
FIG. 17H is a further enlargement of a portion of thehinge body 545 a′″ and thepartial enclosure 592 in which the hinge body is secured and also showing thegap 590 between afirst point 593 a on thelip 587 b of theflange 586 b of thesupport bow 550 and asecond point 593 b at the lower corner of thepanel 536 which is taken from the dashedcircle 17H ofFIG. 17G ; -
FIG. 18A is a schematic illustration similar to that ofFIG. 5A , but illustrating an alternative embodiment of the support bows each having a flange, but neither of which have a flange lip; -
FIG. 18B is a schematic illustration similar to that ofFIG. 5A , but illustrating an alternative embodiment of thehinge body 545 a′ having a single hinge body polymer material and having support bows that have a lip at the end of each of the support flanges of the partial enclosure; -
FIG. 18C is a schematic illustration similar to that ofFIG. 18B , but illustrating a further alternative embodiment of thehinge body 545 a″ made of a single polymeric material and having a flat central portion; -
FIG. 18D is a schematic illustration similar to that ofFIG. 18B , but illustrating a further alternative embodiment of thehinge body 545 a′″ made of a single polymeric material that is secured on each side within a partial enclosure created by thepanel 536 and thesupport bow 550 without an adhesive securing the side portion to the rigid panel; -
FIG. 18E is an enlarged schematic perspective illustration similar to that ofFIG. 17G , but with the hinge body shown partially secured within apartial enclosure 592 created byrigid panels 536, one of which is partially broken away, and support bows having a lip at the end of each of the support flanges of the partial enclosure; -
FIG. 18F is an enlarged schematic perspective view of the portion ofFIG. 18E shown in the dashedcircle 18F, but with the rigid panels and support bows shown only in part; -
FIG. 18G is a further schematic perspective view similar toFIG. 18E but showing the structure of thepartial enclosure 592 with the hinge body shown only partially in phantom, with the rigid panels and support bows shown in cooperation with one another as shown inFIG. 18D ; -
FIG. 18H is an enlarged view providing a transverse vertical cross section of the portion of the folding tonneau cover assembly shown inFIG. 18A , but showing thehinge body 545 a in phantom; -
FIG. 18I is an enlarged view similar to that shown inFIG. 18H , except that thehinge body 545 a is shown in cross section and therigid panels 536 and the support bows 550 are shown in phantom; -
FIG. 18J is an enlarged view of the portion of the foldingtonneau cover assembly 530 shown in the dashedcircle 18J ofFIG. 18I ; -
FIG. 19A is a detail side view of a portion of the folding tonneau cover apparatus ofFIG. 1 as viewed fromline 19A —19A as indicated inFIG. 3A , with the side rail on the driver's side in phantom and the truck removed to show the underlying structure, and showing in phantom an alternate position of the same portion of the folding tonneau cover apparatus in which the rear panel has been lifted up and rotated frontward somewhat so that the hook is disengaged from the catch; -
FIG. 19B is a detail side view similar to that ofFIG. 19A , but in which the rear panel has been rotated completely forward onto the middle a panel; -
FIG. 19C is a schematic illustration of steps and configurations of the folding tonneau cover apparatus ofFIG. 1 showing the folding cover assembly being installed onto the side rails, showing the hooks at the front of the front panel approaching the catches at the front of the side rails, then the hooks at the front of the front panel engaged with the catches at the front of the side rails and the latches at the rear of the front panel engaged with the side rails and the respective containment brackets, then the spacer panel and middle panel unfolded with the hooks at the front of the middle panel engaged with the respective catches on the side rails, then the rear panel unfolded with the hooks at the front of the rear panel engaged with the respective catches on the side rails and the latches at the rear of the rear panel engaged with the respective side rails and containment brackets; -
FIG. 20A is a schematic illustration of the folding tonneau cover apparatus ofFIG. 1 , as configured for a cargo box having angled sides; -
FIG. 20B is a schematic illustration of the folding tonneau cover apparatus ofFIG. 1 , as configured for a cargo box having parallel sides; -
FIG. 20C is a schematic illustration of the folding tonneau cover apparatus ofFIG. 1 , as configured for an elongated cargo box; -
FIG. 20D is a schematic illustration of the folding tonneau cover apparatus ofFIG. 1 , as configured for a shorter cargo box; -
FIG. 20E is a schematic illustration of the folding tonneau cover apparatus ofFIG. 1 , as configured for a cargo box with arbitrary shape; -
FIG. 21A is a schematic illustration of a portion of the folding tonneau cover apparatus ofFIG. 1 , illustrating a flexible hinge interconnecting two adjacent panels, showing bent or bowed support bows creating a bending or bowing of the panels attached thereto (see alsoFIGS. 16B-16E, 16G, 16I, and 16K ), with the bending or bowing exaggerated for illustration, with the panels unfolded; and -
FIG. 21B is a schematic illustration similar to that ofFIG. 21A , showing the panels folded up, and together withFIG. 21A illustrating how the flexible hinge can accommodate the folding up and unfolding of such bent or bowed panels. -
FIG. 22 is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus having a folding cover assembly incorporating a cab panel onto which rear, middle, spacer, and front panels can fold, with the folding tonneau cover apparatus attached to a pickup truck which is shown in phantom, but for clarity of illustration the perimeter seal is not shown; -
FIG. 23 is a bottom plan view of the folding tonneau cover apparatus ofFIG. 22 ; -
FIG. 24 is a partial section view of the rear portion of the folding tonneau cover apparatus ofFIG. 22 as indicated onFIG. 23 and illustrating an edge guard at the rear portion of the rear panel; -
FIG. 25A is schematic illustration of a cross section along a front-back plane of one of the hinges of the folding tonneau cover ofFIG. 22 showing the basic configuration with the hinge unfolded; -
FIG. 25B is a schematic illustration of a cross section along a front-back plane of a preferred embodiment of one of the hinges of the folding tonneau cover ofFIG. 22 showing the hinge unfolded; -
FIG. 25C is a schematic illustration showing the hinge ofFIG. 25B but with the hinge folded about 45 degrees; -
FIG. 26 is a schematic illustration showing the hinge ofFIG. 25B but with the hinge folded about 180 degrees; -
FIG. 27 is a schematic illustration showing a cross section similar to that ofFIG. 25C showing a spacer panel and two adjacent hinges of the folding tonneau cover ofFIG. 22 , illustrating both hinges in a partially folded configuration; -
FIG. 28 is a schematic illustration showing the general steps and configurations of the folding cover assembly ofFIG. 22 as it is folded up; -
FIG. 29 is a side perspective view from the driver's side of the folding tonneau cover apparatus ofFIG. 22 , showing a configuration in which the rear, middle, and spacer panels are folded onto the front panel and secured with storage straps, but for clarity of illustration the perimeter seal is not shown; -
FIG. 30 is a side perspective view similar to that ofFIG. 29 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically, but for clarity of illustration the perimeter seal is not shown; -
FIG. 31A is a side perspective view similar to that ofFIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including cab straps, but for clarity of illustration the perimeter seal is not shown; -
FIG. 31B is a side perspective view similar to that ofFIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a side strap, but for clarity of illustration the perimeter seal is not shown; -
FIG. 31C is a side perspective view similar to that ofFIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a cab panel strap, but for clarity of illustration the perimeter seal is not shown; -
FIG. 31D is a side perspective view similar to that ofFIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a securing magnet, but for clarity of illustration the perimeter seal is not shown; -
FIG. 31E is a side perspective view similar to that ofFIG. 30 , but showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically and secured to the truck cab with a securing member including a securing bracket, but for clarity of illustration the perimeter seal is not shown; -
FIG. 32 is a rear perspective view of an alternate embodiment of folding tonneau cover apparatus according to the present invention, including a support frame assembly, a folded cover forward securing assembly, and a folding cover assembly incorporating a cab panel onto which rear, middle, spacer, and front panels can fold, with the folding tonneau cover apparatus attached to a pickup truck which is shown in phantom; -
FIG. 32A is a top plan view primarily showing the folding cover assembly shown inFIG. 32 ; -
FIG. 32B is a bottom plan view primarily showing the folding cover assembly ofFIG. 32 ; -
FIG. 32C is a side view of portions of the folding tonneau cover apparatus ofFIG. 32 as viewed fromline 32C-32C ofFIG. 32A ; -
FIG. 32D is a detailed view of a portion of the folding tonneau cover apparatus as viewed fromline 32D-32D ofFIG. 32A , illustrating the spacer panel and adjacent hinges; -
FIG. 32E is a detailed view of a portion of the folding tonneau cover apparatus as viewed fromline 32E-32E ofFIG. 32A , illustrating the rear hinge; -
FIG. 32F is an enlarged detailed front perspective view of a portion of the folding tonneau cover apparatus encircled by dashedline 32F-32F ofFIG. 32C , showing a storage retainer and a tether and link; -
FIG. 32G is a side view of the storage retainer shown inFIG. 32F ; -
FIG. 32H is a bottom perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 ; -
FIG. 32I is an enlarged perspective bottom view of the portion of the folding tonneau cover apparatus encircled by the dashed line 32I ofFIG. 32H , illustrating the spacer panel and adjacent hinges and showing a brace retained in a brace retainer; -
FIG. 32J is an enlarged perspective bottom view of the portion of the folding tonneau cover apparatus encircled by the dashedline 32J ofFIG. 32H , illustrating the cab panel and showing a rail clamp bracket and a hex clamp bolt; -
FIG. 32K is an enlarged perspective bottom view similar to that ofFIG. 32J but illustrating an alternative lever clamp bolt; -
FIG. 33A is a rear perspective view a portion of the folding tonneau cover apparatus ofFIG. 32 ; -
FIG. 33B is a partial section view as seen from theline 33B-33B ofFIG. 33A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom; -
FIG. 34A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 32 , with the release cord pulled to pull the latch against the bias of the spring to release the latch from the engagement with the side rail, with the two portions of the release cord pulled for illustration; -
FIG. 34B is a partial section view as seen from theline 34B-34B ofFIG. 34A similar to the view ofFIG. 33B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail; -
FIG. 35A is schematic illustration of a vertical cross section along a front-to-back plane as seen from theline 35A-35A ofFIG. 32A of one of the hinges of the folding tonneau cover assembly ofFIG. 32 showing the basic configuration with the hinge unfolded; -
FIG. 35B is a schematic illustration similar toFIG. 35A of a transverse vertical cross section along a front-to-back plane showing an alternate embodiment of one of the hinges of the folding tonneau cover assembly ofFIG. 32 showing the hinge unfolded; -
FIG. 35C is a schematic illustration showing the hinge ofFIG. 35B , but with the hinge folded at about 45 degrees from the unfolded orientation shown inFIG. 35B ; -
FIG. 35D is a schematic illustration showing the general steps and configurations of the folding tonneau cover assembly ofFIG. 32 as it is folded up into a fully folded orientation; -
FIG. 36A is a rear perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 wherein the latches on the rear panel have been released as inFIG. 34B and the rear panel has been lifted up in a first step toward folding up the folding cover assembly; -
FIG. 36B is a partial section view as seen fromline 36B-36B ofFIG. 36A showing the latch near the driver's side end portion of the rear support bow of the middle panel engaged with the lip of the side rail; -
FIG. 37A is a rear perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 wherein the rear panel has been rotated forward onto the middle panel in a further step toward folding up the cover assembly; -
FIG. 37B is a partial section view as seen from theline 37B-37B ofFIG. 37A showing the latch near the driver's side end portion of the rear support bow of the middle panel engaged with the lip of the side rail; -
FIG. 37C is a partial section view similar to the view ofFIG. 37B , but showing the arrangement with the engaging portion of the latch retracted and disengaged from the lip of the side rail, allowing the middle panel to be lifted up; -
FIG. 38A is a rear perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 , wherein the rear panel is folded over onto the middle panel and wherein both panels have been lifted up and pivoted forward generally about 90 degrees with respect to the front panel that is resting on the side rails and is generally in a horizontal plane with respect to the pickup truck shown in part in phantom; -
FIG. 38B is a partial section view as seen from theline 38B-38B ofFIG. 38A showing theswing latch 562 c near the driver's-side end portion of the support bow of the spacer panel disengaged from thecorresponding catch 564 c; -
FIG. 39A is a rear perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 showing the rear panel together with the middle panel and the spacer panel rotated forward so that the middle panel and the rear panel are resting together on the top of the front panel, with the spacer panel rotated upward generally at a 90 degree angle to the other panels; -
FIG. 39B is a partial section view as seen from theline 39B,C-39B,C ofFIG. 39A illustrating the driver's side of the partially folded tonneau cover assembly showing the engaging portion of the latch near the driver's-side end portion of the support bow of the front panel engaged with the lip of the driver's side side rail and a containment bracket; -
FIG. 39C is a partial section view similar to the view ofFIG. 39B , but showing the arrangement with the engaging portion of the latch retracted and disengaged from the lip of the side rail, allowing the front panel to be lifted up; -
FIG. 39D is a partial section view as seen from theline 39D,E-39D,E ofFIG. 39A illustrating the driver's side of the partially folded tonneau cover assembly showing a storage strap; -
FIG. 39E is a partial section view similar to the view ofFIG. 39D showing the storage strap engaged with a storage retainer to secure the rear, middle, and spacer and front panels to the cab panel; -
FIG. 40 illustrates the folding tonneau cover apparatus ofFIG. 32 , including the folding cover assembly secured in the fully folded-up configuration with two cab braces each engaged with a cab bracket secured to the truck cab; an operator can attach or detach the cab braces from the cab brackets, or actuate the hex bolts or handle bolts to disengage the folding cover assembly from the side rails to remove the folding cover assembly from the support frame assembly or attach the folding cover assembly to the support frame assembly as desired; -
FIG. 40A is a side perspective view of a portion of the tonneau cover apparatus ofFIG. 32 showing a configuration in which the rear, middle, spacer, and front panels are folded onto the cab panel with the rear, middle, and front panels oriented generally vertically; -
FIG. 40B is a side perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 similar to the view ofFIG. 40A , but showing two cab braces each engaged with a cab bracket to hold the folded up tonneau cover assembly in a generally vertical configuration adjacent the truck cab (shown in phantom); -
FIG. 40C is a perspective view of a portion of the folding cover assembly showing the spacer panel and adjacent hinges and a support bow having a cab brace secured to the support bow for storage; -
FIG. 40D is a perspective view similar to that ofFIG. 40C but with the cab brace rotated outward so that it can be secured to a cab bracket; -
FIG. 40E is a side perspective view of a portion of the folding tonneau cover apparatus ofFIG. 32 similar to the view ofFIG. 40B , but including an auxiliary support bow to which the two cab braces are attached, and showing the two cab braces each engaged with a cab bracket assembly to hold the folded up tonneau cover assembly in a generally vertical configuration adjacent the truck cab (shown in phantom); -
FIG. 40F is an exploded perspective view of a portion of the cab bracket assembly shown inFIGS. 40B, 40E , and elsewhere herein; -
FIG. 40G is a section view as seen from line G-G ofFIG. 40F showing a cab bracket body; -
FIG. 40H is a perspective view of the cab bracket assembly ofFIG. 40F also showing a cab bracket adhesive; -
FIG. 41 is a rear perspective view of an alternate embodiment of folding or hinged tonneau cover apparatus according to the present invention, including a support frame assembly and a folding or hinged cover assembly, with the hinged tonneau cover apparatus attached to a pickup truck which is shown in phantom; -
FIG. 42A is a top plan view showing the hinged cover assembly of inFIG. 41 ; -
FIG. 42B is a bottom plan view primarily showing the hinged cover assembly ofFIG. 41 and showing retainer bolts which are handle bolts; -
FIG. 42C is a side view of portions of the hinged tonneau cover apparatus ofFIG. 41 as viewed fromline 42C-42C ofFIG. 42A ; -
FIG. 42D is an enlarged detailed view of a portion of the hinged tonneau cover apparatus encircled by dashedline 42D-42D ofFIG. 42C ; -
FIG. 42E is a bottom perspective view of a portion of the hinged tonneau cover apparatus ofFIG. 41 ; -
FIG. 42F is a detail bottom perspective view of the portion of the hinged cover assembly ofFIG. 41 encircled by dashedline 42F-42F ofFIG. 42E ; -
FIG. 42G is a partial section view as seen from theline 42G-42G ofFIG. 42A illustrating the driver's side of the hinged tonneau cover apparatus; -
FIG. 42H is a bottom plan view of an alternate hinged tonneau cover apparatus showing an alternate hinged cover assembly similar to that shown inFIG. 41 but having retainer bolts which are hex bolts; -
FIG. 42I is a detail bottom perspective view similar toFIG. 42F but of a portion of the hinged cover assembly ofFIG. 42H , showing one of the hex bolts and a hinge support; -
FIG. 43A is a rear perspective view of the hinged cover assembly ofFIG. 42H , with the hinged tonneau cover apparatus attached to a pickup truck which is shown partially and in phantom; -
FIG. 43B is a partial section view as seen from theline 43B-43B ofFIG. 43A illustrating the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail, and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom; -
FIG. 44A is a rear perspective view of the folding tonneau cover apparatus ofFIG. 42H similar to the view ofFIG. 43 a , but with a release cord pulled to pull the latch to release the latch from the engagement with the side rail, with two portions of the release cord pulled for illustration; -
FIG. 44B is a partial section view as seen from theline 44B-44B ofFIG. 44A similar to the view ofFIG. 43B , but showing the arrangement with the engaging portion of the latch retracted from the closed position where the latch would be engaged with the lip of the side rail; -
FIG. 45 is an enlarged detailed view of the portion of the hinged tonneau cover apparatus ofFIG. 42H similar to that shown inFIG. 42D , except that some parts have been removed to reveal underlying structures including a hinge support, and the rear panel has been lifted up about 30 degrees; -
FIG. 46 is an enlarged detail side view of the hinge support ofFIG. 45 ; -
FIG. 47 is a perspective view of the hinge support ofFIG. 45 ; and -
FIG. 48 is a rear perspective view of the hinged tonneau cover apparatus ofFIG. 42H with the cover partially lifted up to access the cargo box. - Referring now to the drawings, a folding
tonneau cover apparatus 510 of the present invention is attachable to sidewalls 6 a, 6 b of acargo box 5, such as the cargo box of a truck orpickup truck 2, which is shown in phantom. InFIG. 1 , the foldingtonneau cover apparatus 510 is shown in a typical application covering thetop opening 6 f (shown in phantom inFIG. 12 ) of thecargo box 5 of thepickup truck 2. Thepickup truck 2 and thecargo box 5 and thesidewalls front wall 6 c (FIG. 12 ) at the forward end of thecargo box 5 and thetailgate 6 d at the rear end of thecargo box 5 are not a part of the present invention, but are shown in phantom to illustrate a typical application and function of the foldingtonneau cover apparatus 510 in covering acargo box 5, which has alength 7 a and awidth 7 b. The perimeter of thecargo box 5 includes the forward end orfront wall 6 c, the opposingsidewalls tailgate 6 d, which is shown in part. The rearward end ortailgate 6 d preferably can be opened or closed. It will be appreciated that the perimeter of the top opening of thecargo box 5 will include top surfaces of thefront wall 6 c, the twosidewalls tailgate 6 d when the tailgate is in a closed position (not shown). As further illustrated inFIGS. 2A-3B , the foldingtonneau cover apparatus 510 includes a folding tonneau cover assembly, tonneau cover assembly or coverassembly 530 and asupport frame assembly 518, including side rails or rails 520 a and 520 b. In preferred embodiments, side rails 520 a and 520 b are secured to sidewalls 6 a and 6 b withclamps 514. In preferred embodiments, thefolding cover assembly 530 is configured to be opened to an open position and closed to a closed position, and easily removed and reinstalled by a driver or other operator 8 (FIG. 12 ), as needed. The side rails 520 a and 520 b are constructed and arranged to facilitate securement of thefolding cover assembly 530 to the side rails 520 a and 520 b. In some embodiments, the side rails 520 a and 520 b have aside rail lip 524 and a siderail engagement portion 522 a. In this example, there are eightclamps 514 arranged to hold the side rails 520 a and 520 b to thesidewalls pickup truck 2, but other numbers ofclamps 514 can be used. In some embodiments, the clamps include anouter member 516 a, aninner member 516 b, aclamp engagement portion 516 c, and afastener assembly 516 d; the fastener assembly can, for example, include abolt 516 e, awasher 516 f and anut 516 g as illustrated. - Referring again to
FIGS. 2A-2C , the foldingtonneau cover apparatus 510 ofFIG. 1 is shown in whole or in part, but thetruck 2 and thecargo box 5 are not shown.FIG. 2A shows a top view of the foldingtonneau cover assembly 530 ofFIG. 1 . The top 532 a of thefolding cover assembly 530 is shown. Thefolding cover assembly 530 includes rigid panels orpanels 536. In this example,panels 536 include arear panel 536 a, amiddle panel 536 b, afront panel 536 c, and a spacer panel or hingepanel 536 d. For ease of discussion,panels 536 are specifically referenced herein as 536 a-536 d, and non-specifically or collectively referenced asrigid panels 536. Thefolding cover assembly 530 includes a plurality of suchrigid panels 536, and could potentially have from two to 8panels 536; for example, 6panels 536 could be used, including 4 “longer” panels (similar topanels 536 a-536 c shown herein) and 2 “shorter” panels (similar topanels 536 d shown herein). While a smaller or a larger number ofpanels 536 can be used (not shown), the inventors have found that the configurations illustrated herein provide a good trade-off of convenient folded configuration vs. complexity. - As shown in
FIG. 2A , and also as further described herein with respect toFIGS. 20A-20E , thelength 539 of each of thepanels 536 a-536 d is indicated as 539 a-539 d, respectively. In this example, thespacer panel 536 d has a substantiallysmaller length 539 d than the other panels, as will be further described herein. In preferred embodiments, thelength 539 d of thespacer panel 536 d is preferably no greater than about one-third of thelength 539 a-539 c of theother panels 536 a-536 c.Panels 536 a-536 d can havesimilar length 539, or the length of some or all ofpanels 536 a-536 d can differ. Thewidth 540 of each of thepanels 536 a-536 d is indicated as 540 a-540 d, respectively.Panels 536 a-536 d can have thesame width 540, or the width of some or all ofpanels 536 a-536 d can differ. Theside angle 542 of each of thepanels 536 a-536 d is indicated as 542 a-542 d, respectively, inFIG. 20A .Panels 536 a-536 d can have thesame side angle 542, or theside angle 542 of some or all ofpanels 536 a-536 d can differ. Alternative configurations of folding tonneau covers 530 appropriate for covering thecargo box 5 of various models ofpickup truck 2 are further described below. Eachpanel 536 has a top surface 537 and a bottom surface orunderside 538;panel 536 a has atop surface 537 a and a bottom surface orunderside 538 a,panel 536 b has atop surface 537 b and a bottom surface orunderside 538 b,panel 536 c has atop surface 537 c and a bottom surface orunderside 538 c,panel 536 d has atop surface 537 d and a bottom surface or underside 538 d. - As further described herein and illustrated in drawing
FIGS. 2A-5F , the present invention includes a foldingtonneau cover assembly 530 having a plurality ofrigid panels 536 arranged in a series, with adjacentrigid panels 536 secured to each other by aflexible hinge 544, so that the folding covertonneau cover assembly 530 can be unfolded to cover atop opening 6 f (FIG. 12 ) of acargo box 5 of atruck 2, and folded up to uncover at least a portion of thetop opening 6 f of thecargo box 5 of thetruck 2. Eachrigid panel 536 has afront edge 541 b and arear edge 541 c and a driver'sside edge 541 d and apassenger side edge 541 e and a top surface 537 and a bottom surface orunderside 538. When the foldingtonneau cover assembly 530 is unfolded and arranged to cover thetop opening 6 f of thecargo box 5, each of therigid panels 536 extends between the driver'sside 3 a and thepassenger side 3 b of thecargo box 5, and eachflexible hinge 544 extends between the driver's side and the passenger side of the cargo box. In embodiments having 4rigid panels 536, for example, there are 3flexible hinges 544, eachflexible hinge 544 being secured to two adjacentrigid panels 536. Other configurations are possible, including embodiments having tworigid panels 536 and oneflexible hinge 544, embodiments having threerigid panels 536 and twoflexible hinges 544, embodiments having fiverigid panels 536 and fourflexible hinges 544, embodiments having sixrigid panels 536 and fiveflexible hinges 544, and so forth. In preferred embodiments, the number ofrigid panels 536 is 1 greater than the number offlexible hinges 544; alternative embodiments include foldingtonneau cover assemblies 530 having at least threerigid panels 536 and at least oneflexible hinge 544, as described herein, and at least one other hinge or connection as may be known in the art (not shown) have been envisioned by the inventors. The present invention includes such embodiments, as long as the embodiments include at least oneflexible hinge 544 as described herein. - Also illustrated in
FIG. 2A , is aprotective film 574 on thetop surface 537 c of thefront panel 536 c. As described further herein and illustrated inFIGS. 2A, 9A, 10A, and 10 B, alternate embodiments of the foldingtonneau cover assembly 530 include theprotective film 574, which protects thetop surface 537 c of thefront panel 536 c when the foldingtonneau cover assembly 530 is folded up and thestandoffs 558 are in contact with thetop surface 537 c. As described below, aprotective pad 558 a is preferably attached to the bottom of eachstandoff 558, but abrasion of thetop surface 537 c can occasionally occur when theprotective pads 558 a are in direct contact with thetop surface 537 c, especially when the pickup truck on which thefolding cover assembly 530 resides is travelling on rough road surfaces that cause theprotective pads 558 a to vibrate on thetop surface 537 c. While theprotective film 574 is optional to reduce or prevent such abrasion in some embodiments, they are not required. Such alternate embodiments of the present invention, which include theprotective film 574 to minimize abrasive damage to thetop surface 537 c, are disclosed herein.Protective film 574 can be obtained from a variety of suppliers, including Avery Dennison (Glendale, Calif.), 3M (St. Paul, Minn.), Arlon (Placentia, Calif.), and Xpel (San Antonio, Tex.). One preferredprotective film 574 is Avery Dennison SW 900 Series Supreme Wrapping Film. Theprotective film 574 is preferably applied to specific locations on thetop surface 537 c which will align with thestandoffs 558 when the foldingtonneau cover assembly 530 is folded up as shown and described herein. For example, for embodiments including 4standoffs 558, protective film can be applied to thetop surface 537 c in the locations shown inFIG. 2B . Theprotective film 574 is preferably located in locations on thetop surface 537 c as schematically illustrated onFIG. 2A that correspond to the locations that theprotective pads 558 a of thestandoffs 558 will assume when they engage thetop surface 537 c of thefront panel 536 c, when thefolding cover assembly 530 is in a fully folded up orientation. -
FIG. 2B shows a bottom view of the foldingtonneau cover apparatus 510. Visible in this view are hinges orflexible hinges 544, which are situated betweenadjacent panels 536 and adjoinadjacent panels 536. For ease of discussion, hinges 544 are specifically referenced herein as 544 a-544 c, and non-specifically or collectively referenced as 544. Specifically, situated between therear panel 536 a and themiddle panel 536 b is hinge 544 a. Similarly, situated between themiddle panel 536 b and thespacer panel 536 d is hinge 544 b, and situated between thespacer panel 536 d and thefront panel 536 c ishinge 544 c.Hinges 544 allow thefolding cover assembly 530 to be folded up and will be more fully described below. Support bows 550 are attached to thepanels 536 to provide additional support and rigidity to thepanels 536, and also provide a structure for mounting of various other components as described in detail later herein. For ease of discussion, support bows 550 are specifically referenced herein as 550 a-550 g, and non-specifically or collectively referenced as 550. The foldingtonneau cover assembly 530 is removably secured to thesupport frame assembly 518 by securingapparatus 551 a. Preferably, securingapparatus 551 a includes at least one lockingmember 551 b which is engageable and disengageable from thesupport frame assembly 518. Preferably, the lockingmember 551 b includes latches 552 which are located at the support bows as shown and secure thefolding cover assembly 530 to the side rails 520 a and 520 b. Release cords 554 are attached to the latches 552. For ease of discussion, latches 552 are specifically referenced herein as 552 a-552 d, and non-specifically or collectively referenced as 552. Also for ease of discussion, release cords 554 are specifically referenced herein as 554 a-554 b, and non-specifically or collectively referenced as 554. The release cords 554 pass through cord guides 555 which are attached to supportbows 550 as shown. Cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b, which will be described in further detail below.Standoffs 558 are shown, and will be described in further detail below. Sidebars or handles 559 are attached topanels panel 536 to further support thepanels 536.Perimeter seal 534 is located on the bottom 532 b of thefolding cover assembly 530 and is arranged to seal against top of the perimeter of thecargo box 5 at thesidewalls front wall 6 c and thetailgate 6 d of thecargo box 5 as shown; some portions ofperimeter seal 534 are behind side rails 520 a and 520 b and not visibleFIG. 2B . Theperimeter seal 534 is further described herein. - The support bows or transverse frame members or
channels 550 provide additional support for thepanels 536. In this embodiment, the panels each have two support bows 550, one located near each of the front and rear ends of eachpanel 536, except for thespacer panel 536 d, which has only asingle support bow 550. In this embodiment, there are latches 552 mounted in pairs, one of each pair mounted near each end of each of the support bows 550 a and 550 f as shown. As further described below, the latches 552 engage the side rails 520 a and 520 b to secure thefolding cover assembly 530, and can slide a short distance towards or away from the side rails 520 a and 520 b to engage or release thefolding cover assembly 530 or portions thereof or selectedpanels 536 from the side rails 520 a and 520 b as further described below. Note that the support bows 550 b, 550 c, 550 d, 550 e, and 550 g do not have associated latches 552 in this embodiment. In this embodiment, there are two latch release cords or release cords or cords 554, each of which are connected to opposing pairs of latches 552 which secure thepanels 536 to the side rails 520 a and 520 b. The release cords 554 preferably pass through cord guides 555 which are mounted to the support bows 550; the release cords 554 can slide within or behind the cord guides 555 as further described herein. The release cords 554 generally extend from the latches 552 along the support bows 550. As illustrated inFIGS. 2B and 2C , theclamps 514 secure the side rails 520 a and 520 b to thesidewalls cargo box 5. The foldingtonneau cover apparatus 510 is seen in a side view from the driver's side inFIG. 2C . - In further reference to
FIGS. 2C-2E , the portion of the foldingtonneau cover apparatus 510 that includes therear hinge 544 a, as indicated by the encircled area labeled 2D inFIG. 2C , is illustrated in an enlarged partial cutaway view inFIG. 2D . Similarly, the portion of the foldingtonneau cover apparatus 510 that includes the middle and front hinges 544 b and 544 c, respectively, as indicated by the encircled area labeled 2E inFIG. 2C , is illustrated in an enlarged partial cutaway view inFIG. 2E . Thefolding cover assembly 530 preferably includes extended hinge support flange(s) 586 located adjacent the bottom surface orunderside 538 of therespective panel 536 and near the front andrear edges rigid panels 536 to which theflexible hinges 544 are secured (for example,FIG. 5A ). As will be described in further detail below, theflexible hinges 544 each preferably includes aflexible hinge body 545 a which includes acentral portion 546 a,side portions intermediate portions side portion hinge support flange 586 and therigid panel 536. Adhesive 570 a is preferably located between eachside portion 546 b and the respectiverigid panel 536 to protect against passage of debris or precipitation into thecargo box 5; the adhesive 570 a can also aid in securement of thehinge body 545 a to the respectiverigid panel 536. The support bows orchannels 550 are preferably secured to the bottom surface orunderside 538 of therigid panels 536, near thefront edge 541 b and/orrear edge 541 c of therigid panels 536. Eachsupport bow 550 that is adjacent aflexible hinge 544 preferably includes the extendedhinge support flange 586. Further details regarding the structure of theflexible hinge body 545 a and securement to therigid panels 536 are described below. - The folding
tonneau cover apparatus 510 preferably includescontainment brackets containment bracket 525 a is further illustrated inFIG. 2F . Note that inFIG. 2F , portions of therigid panels 536 and theflexible hinges 544 are broken away to reveal the underlying structure, and many elements are illustrated in phantom to emphasize the elements being described. When the engagingportion 553 b is engaged under theside rail 520 a and is contained by the containment bracket oranchor socket 525 a as illustrated inFIG. 2F , the engagingportion 553 b is contained by thecontainment bracket 525 a so that it cannot slide frontwards or rearwards along theside rail 520 a. Thecontainment bracket 525 a is preferably secured to the side rail by afastener assembly 526, which may include a bolt, nut, washer, or other fasteners known in the art. In this configuration, thespring 556 is urging thelatch slide 553 outwards towards theside rail 520 a. To release the latch 552 and allow thefolding cover assembly 530 to be lifted off and removed from the side rail 520, the release cord 554 e is pulled. When the release cord 554 e has been pulled, retracting thelatch slide 553 and compressing thespring 556, and disengaging the engagingportion 553 b from theside rail 520 a and thecontainment bracket 525 a, and releasing the latch 552, the configuration is as illustrated in phantom inFIG. 2F . Theside rail 520 b preferably has a mirror-image configuration to theside rail 520 a, with a siderail front portion 521 c and side railrear portion 521 d, and acontainment bracket 525 b functioning in a similar manner. - Some embodiments include the
alternative side rail 520 c which includes a plurality of sections 521 as illustrated inFIG. 2G ; theside rail 520 c preferably includes siderail front portion 521 a and side railrear portion 521 b. Thecontainment bracket 525 a is preferably secured to theside rail 520 c by afastener assembly 526, which may include abolt 516 e,nut 516 f,washer 516 g, or other fasteners known in the art. In these embodiments, in addition to its function to retain the latch 552 as previously described, thecontainment bracket 525 a preferably facilitates securement of the siderail front portion 521 a and side railrear portion 521 b together. One advantage of the “split”side rail 520 c is that storage and shipment of the side rail 520 can be more practical; a one-piece side rail would be long and in some cases could be more difficult or expensive to transport, for example. Theside rail 520 d preferably has a mirror-image configuration to theside rail 520 c, with a siderail front portion 521 c and side railrear portion 521 d, and acontainment bracket 525 b functioning in a similar manner as the similar elements just described. Thealternative side rail 520 c,containment bracket 525 a, andfastener assembly 526 are illustrated in exploded view inFIG. 2H . Preferably, atether 580 is attached to thecontainment bracket 525 b and is releasably secured by alink 581 when desired to aring 582 that is secured to thesupport bow 550 e; this arrangement provides additional stabilization of thefolding cover assembly 530 when thefolding cover assembly 530 is secured to the side rails 520 a, 520 b and will secure thefolding cover assembly 530 to the side rail 520 if other attachments fail. - In describing preferred embodiments of the present invention in the description that follows, it will be appreciated that reference will be made either to the “driver's side” or “passenger side” or to the “front” or to the “rear” of the folding tonneau cover apparatus or portions thereof in a manner that is consistent with the orientation of the folding tonneau cover apparatus when it is secured to a vehicle as envisioned, so that the “rear” of a folding tonneau cover apparatus or portion thereof will be consistent with what is seen when one is looking at the rear of such a vehicle when the folding tonneau cover apparatus or portion(s) thereof are attached to such a vehicle as envisioned herein, or such portion thereof which is closer to the rear. The “driver's side” refers to the side corresponding to the side of the vehicle typically used by the driver to operate the vehicle in North America, and the “passenger side” refers to the side opposite the “driver's side”. For clarity, the “length” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein, refers to a measurement of the “front” to “rear” dimension, since the pickup truck and the cargo box are typically longer in that direction. Similarly, “width” of the folding tonneau cover apparatus, the folding cover assembly, the hinges, and the panels described herein, generally refers to the “driver's side” to “passenger side” direction, since the pickup truck and the cargo box are typically shorter in that direction. However, these terminologies, that are used as a matter of convenience, are not intended to be limiting; the folding tonneau cover apparatus could be shorter in the “length” direction than in the “width” direction, for example. For other items such as support bows and sidebars, “length” has the normal meaning, referring to the longer dimension or to the dimension along an extruded shape, for example; any potential confusion in terminology can be eliminated by examination of the various Figures in the accompanying drawings.
- Referring now to
FIGS. 3A and 3B , therelease cord 554 a near the rear end of therear panel 536 a passes through cord guides 555, 555 a, 555 b.FIG. 3B is an enlarged partial section view of the driver's side end portion of thesupport bow 550 a as indicated inFIG. 3A . The cord guides 555 are preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer. In alternate embodiments, the cord guides 555 can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process. One of thestandoffs 558 can be seen inFIG. 3A , and will be described in more detail later. - As seen in
FIG. 3B , the latch 552 includeslatch slide 553 having an engagingportion 553 b which extends forward to engage thelip 524 of theside rail 520 a, so as to secure therespective panel 530 to theside rail 520 a. Thelatch slide 553 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, thelatch slide 553 includes fiberglass-reinforced nylon. Thelatch slide 553 is biased by a biasing member orspring 556 towards theside rail 520 a so that the engagingportion 553 b engages theside rail 520 a to form a secured configuration in which therespective panel 530 is restricted from being lifted up from thecargo box 5; in this example, thespring 556 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias thelatch slide 553 towards theside rail 520 a so that the engagingportion 553 b engages theside rail 520 a so that the latch 552 is in the secured configuration. In this embodiment, thespring 556 is held between thelatch slide 553 and a spring retainer assembly 557. The spring retainer assembly 557 is secured in the desired location in thesupport bow 550 a. The side rails 520 a and 520 b preferably include extruded metal, and have a siderail engagement portion 522 a (FIG. 3B ), arranged to approximate a portion of thesidewall pickup truck 2. Theclamp 514 is shown in detail inFIG. 3B . Theclamps 514 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.Clamps 514 preferably have anouter member 516 a and aninner member 516 b which are tightened towards each other and held as an assembly on thesidewall 6 a by afastener assembly 516 d which preferably includes abolt 516 e, awasher 516 f, and anut 516 g. Preferably,inner member 516 b has aclamp engagement portion 516 c which, together with siderail engagement portion 522 a ofside rail 520 a, aids in securing theclamps 514 in place on theside rail 520 a. Preferably, theclamps 514 are arranged and tightened to secure theside rail 520 a to thesidewall 6 a, with asidewall gasket 522 c arranged between theside rail 520 a and thesidewall 6 a as illustrated. Abow end cap 565 is located at the end of thesupport bow 550 a. A release cord 554 and a cord guide 555 are shown, and will be described in further detail herein. In the present example, the siderail engagement portion 522 a is a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of thesidewall FIG. 3B , a portion of thesidewall 6 a of acargo box 5 of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a siderail engagement portion 522 a along the length of the side rails 520 a and 520 b that are appropriately configured and oriented. In this example, thecargo box 5 of thepickup truck 2 includes asidewall cap 6 e, butother cargo boxes 5 lack a sidewall cap. Asidewall 6 a andsidewall cap 6 e are similarly illustrated in subsequent drawings herein, includingFIGS. 6B, 7B, 8B and 9B. Preferably, the side4 B rail engagement portion 522 a has a siderail engagement feature 522 b, such as ridges, knurling, surface patterns or textures, or other features which aid in securing theclamps 514. Preferably, asidewall gasket 522 c preferably made of polymeric material is located between the siderail engagement portion 522 a and thesidewall 6 a; thesidewall gasket 522 c can provide protection against damage to thesidewall 6 a by abrasion against theside rail 520 a. Other flexible material can also be used. Thesidewall gasket 522 c can provide leak resistance to prevent water, dust, or other debris from passing into thecargo box 5 along the siderail engagement portion 522 a. Theside rail 520 a has a flange orside rail lip 524 along the length of theside rail 520 a. Theside rail lip 524 provides support for thefolding cover assembly 530. In addition, theside rail lip 524 provides a feature for engagement of the engagingportion 553 b of the latches 552. The driver's side portion of thesupport bow 550 a is shown inFIG. 3B ; the other end of thesupport bow 550 a (toward the passenger side) has a mirror-image configuration, with a latch 552engaging side rail 520 b, andside rail 520 b being attached tosidewall 6 b in a similar manner. - As illustrated in
FIGS. 4A and 4B , when it is desired to release the latches 552 at the rear end of therear panel 536 a, therelease cord 554 a can be pulled, which will retract each of the latches 552 against the force of the respective biasing member orspring 556. Typically, therelease cord 554 a will be pulled as illustrated inFIG. 4A , by a driver (not shown) who has walked to the rear of thecargo box 5 and has opened thetailgate 6 d and reaches in to access and pull therelease cord 554 a. When therelease cord 554 a is pulled, the engagingportion 553 b of the latch 552 is retracted away from thelip 524 of theside rail 520 a as shown inFIG. 4B , releasing the latch 552 from theside rail 520 a and allowing the rear portion of therear panel 536 a to be lifted up from theside rail 520 a. The cord guides 555 adjacent to the latches 552 help to maintain alignment of the ends of therelease cord 554 a so that the latches 552 are retracted in alignment with thesupport bow 550 a, to avoid excessive friction, wear and potential binding. The driver's side portion of thesupport bow 550 a is shown inFIG. 4B ; the other end of thesupport bow 550 a (toward the passenger side) has a mirror-image configuration, and when therelease cord 554 a is pulled, the latches 552 at both ends of thesupport bow 550 a are retracted, so that the rear end of therear panel 536 a can be lifted up from bothside rails - Referring now also to
FIGS. 5A-5D , which illustrate a portion of thefolding cover assembly 530 in schematic cross section views as indicated by theline 5A-5A inFIG. 2A , each of the hinges 544 (544 a, 544 b, and 544 c) preferably includes theflexible hinge body 545 a which is elongated and extends between the driver'sside 3 a and thepassenger side 3 b of thecargo box 5 when thefolding cover assembly 530 is unfolded to cover thecargo box 5. Theflexible hinge body 545 a has a hingelongitudinal axis 545 b which is oriented along the length of thehinge body 545 a, and ahinge body profile 545 c, which is the shape of a transverse vertical cross section taken perpendicular to the hingelongitudinal axis 545 b. Thehinge body profile 545 c is preferably uniform along the hingelongitudinal axis 545 b of thehinge body 545 a. In embodiments having more than oneflexible hinge 544, each of theflexible hinges 544 can have a similarhinge body profile 545 c. Alternatively, thehinge body profile 545 c of theflexible hinge bodies 545 a can differ from the profile of at least one other of theflexible hinge bodies 545 a. - The folding
tonneau cover assembly 530 of the present invention may include one of several differenthinge body embodiments FIGS. 17C-18F ). Thefirst embodiment 545 a, shown inFIGS. 5A-5C andFIGS. 17A-17D , is a dual durometer hinge having a moreflexible polymer material 547 c making up thecentral portion 546 a and a portion of theintermediate portion central portion 546 a, and a more rigid orstiff polymer material 547 d making up theside portions intermediate portion central portion 546 a of the first embodiment of thehinge body 545 a. The first embodiment of thehinge body 545 a will take more than one form depending on the format of the adhesive material attached to the hinge body for the purpose of sealing and sealing thehinge body 545 a to the underside of the respectiverigid panels 536 on either side of therespective hinge hinge body 545 a shown inFIG. 5A , hingebody 545 a is secured to the underside of the respectiverigid panels 546 by anadhesive material 570 a described elsewhere herein. In reference to thehinge body 545 a shown inFIG. 5B , hingebody 545 a is secured to the underside of therigid panels adhesive member 571 a described elsewhere herein. In reference to thehinge body 545 a shown inFIG. 5C , thehinge body 545 a is secured to the underside of the respectiverigid panels third layers FIGS. 17A-17D in the first adhesive format employing theadhesive material 570 a. - A further embodiment of the
hinge body 545 a′ having similar adhesive 570 a for sealing and securing thehinge body 545 a′ to the underside ofrigid panels 536 but having only a single durometer polymer design is shown inFIG. 17E . This single-durometer embodiment of thehinge body 545 a′ is also shown inFIG. 18B , but with a different adhesive 571 format. A further embodiment of thehinge body 545 a″ is shown inFIG. 18C and is generally the same as the single-durometer hinge body 545 a′ shown inFIG. 18B , except that thecentral portion 546″ of thehinge body 545 a″ does not include a concave upper surface likehinge body 545 a′, but has instead a flatcentral portion 546″ in which water will not pool or run off along the length of the hinge body toward the sidewalls of thepickup truck 2. Thehinge body 545 a′″ shown inFIGS. 17F-17H andFIGS. 18D-18F is also a single-durometer hinge body made of aflexible polymer material 547 c and it does not need an adhesive member to secure it to the underside of the rigid panels, because the close proximity of therigid panel 536 and thesupport bow 550, which has hahinge support flange 586 having aflange lip 587, which cooperate to form apartial enclosure 592, described elsewhere herein, which will hold thehinge body 545 a′″ in place on each side of thehinge body 545 a′″ as shown inFIGS. 17G, 17H, and 18D-18F . The inventors have found that even when adhesive 570 a, 5701 a, or other adhesives or adhesive members as described herein are not required for securement of thehinge body partial enclosure 592, such adhesives or adhesive members can be advantageously included to provide a seal between the hinge body and the respectiveadjacent panels 536 against intrusion by moisture or debris into thecargo box 5 when thefolding cover apparatus 530 is unfolded and covering thecargo box 5. - The
flexible hinge body 545 a′″ preferably includes asingle polymer material 547 a, and provides an effective barrier against influx of moisture, precipitation or debris into thecargo box 5 between the adjacentrigid panels 536 when thefolding cover assembly 530 is unfolded and in place covering thecargo box 5. The hingebody polymer material 547 a preferably includes anelastomeric polymer material 547 b and more preferably includes a thermoplastic polymer. Theelastomeric polymer material 547 b is preferably extruded to form an elongated structure having the desiredhinge body profile 545 c. Examples of the preferableelastomeric polymer material 547 b include Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer and Sarlink® TPV 5765B thermoplastic vulcanizate, both available from Teknor Apex Company, Pawtucket, R.I. - Each
flexible hinge body 545 a preferably includes the twoside portions central portion 546 a located between the twoside portions flexible hinge body 545 a preferably includes the twointermediate portions intermediate portions central portion 546 a and one of the tworespective side portions central portion 546 a,side portions intermediate portions flexible hinge body 545 a preferably extend along the length of theflexible hinge body 545 a, and thehinge thickness 545 d of the central, side, andintermediate portions 546 a-546 e together at least partially define thehinge body profile 545 c. Each of the twoside portions rigid panel 536. When it is desired to fold up the foldingtonneau cover assembly 530, one of the adjacentrigid panels 536 is lifted up and folded towards the other of the adjacentrigid panels 536, and thecentral portion 546 a bends to function as a hinge as further described herein. - In some embodiments, such as schematically illustrated in
FIGS. 5A-5C , theflexible hinge body 545 a includes more than one polymeric material such as those described herein; for example, theflexible hinge body 545 a may include a softer or lower-durometerelastomeric polymer material 547 c and a harder or higher-durometerelastomeric polymer material 547 d. Thecentral portion 546 a preferably includes the softerelastomeric polymer material 547 c, and theside portions rigid panels 536 as stated, preferably include the harderelastomeric polymer material 547 d. In such embodiments, a transition or mixing of the materials preferably occurs in theintermediate portions central portion 546 a being more flexible in bending than theintermediate portions side portions flexible hinge body 545 a preferentially occurs in thecentral portion 546 a, although some flexing and bending can occur in other portions of theflexible hinge 544 in addition to the central portion. This arrangement is schematically illustrated inFIG. 5C , which shows the hinge illustrated inFIG. 5B somewhat bent. In the drawings, which illustrate embodiments of thehinge body 545 a having more than one polymeric material, theintermediate portions intermediate portions - For example, in one preferred embodiment, the
central portion 546 a includes the softerelastomeric polymer material 547 c, one example of which is Sarlink® TPE RV-2250D BLK 111 thermoplastic elastomer, and theside portions elastomeric polymer material 547 d, one example of which is Sarlink® TPV 5765B thermoplastic vulcanizate. These materials can be extruded together to form the disclosed structure, with a mixing of these materials occurring in theintermediate portions thickness 545 d of the various portions of theflexible hinge body 545 a can also affect the bending properties, but the variation of polymeric materials as just described can be useful in facilitating bending of thehinge 544 in thecentral portion 546 a, which in use is located between theadjacent panels 536, and in facilitating securement of theside portions adjacent panels 536. - While forming the
flexible hinge body 545 a by extrusion of thermoplastic elastomers such as those listed above is preferred, other materials and fabrication methods can be utilized. For example, theflexible hinge body 545 a can include a structure fabricated by molding or other additive or subtractive manufacturing process. Theflexible hinge body 545 a may have additional material added, such as reinforcing fibers or filaments (not shown) adhered to or incorporated into theflexible hinge body 545 a, including cloth-inserted, cloth-reinforced, fiberglass-reinforced, and fiber-reinforced polymer materials. The hingebody polymer material 547 a can include a vinyl material, natural or synthetic rubber or other flexible polymeric material, EPDM rubber, neoprene rubber, nitrile rubber, latex, silicone rubber, polyurethane material, or other polymer materials known in the art, or combinations of materials. Theflexible hinge body 545 a preferably includes a flexible material that can withstand deformation without failure due to cracking or breakage to allow bending of thehinge 544 to fold up thefolding cover assembly 530, and that is moisture-resistant to avoid leakage into thecargo box 5. - As stated above, adhesive 570 a is preferably located between each
side portion 546 b and the respectiverigid panel 536 as illustrated inFIG. 5A to protect against passage of debris or precipitation into thecargo box 5; the adhesive 570 a can also aid in securement of theflexible hinge 544 to the respectiverigid panel 536. The adhesive 570 a can include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between therigid panel 536 and the respectiveflexible hinge 544 or to secure theflexible hinge 544 to the respectiverigid panel 536. In some preferred embodiments, the adhesive 570 a includes a double-sidedadhesive tape 571 a, which preferably includes anacrylic foam material 572 a, withadhesive layer 572 b arranged on one side of theacrylic foam material 572 a, andadhesive layer 572 c arranged on the other side of theacrylic foam material 572 a, for example. For example, the double-sidedadhesive tape 571 a can be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), theadhesive layer 572 b includes heat-activated adhesive and anadhesive layer 572 c includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer 572 c. Preferably, theadhesive layer 572 b (in this example, heat-activated adhesive) is aligned with theflexible hinge body 545 a while the heat-activated adhesive is activated to adhere the double-sidedadhesive tape 571 a to theflexible hinge body 545 a; theflexible hinge body 545 a together with the attached double-sidedadhesive tape 571 a is subsequently aligned with therigid panel 536 and the release strip is removed. Preferably, after theadhesive layer 572 c is aligned with thepanel 536, theflexible hinge body 545 a is attached to therigid panel 536 by activating theadhesive layer 572 c (in this example, pressure-sensitive adhesive). The adjacentrigid panel 536 is similarly attached to theflexible hinge body 545 a with double-sidedadhesive tape 571 a forming the structure ofhinge 544 illustrated inFIG. 5B . Theflexible hinge body 545 a allows thehinge 544 to take a flat or open configuration as illustrated inFIGS. 5A and 5B , or to flex or bend as illustrated inFIGS. 5C, 7C , and other figures herein, providing aflexible hinge 544 that allows thefolding cover assembly 530 to fold as illustrated throughout the Figures and described herein, withrigid panels 536 folding up and rotating towards otherrigid panels 536 as shown. Preferably, theflexible hinge body 545 a is adhered to the respective bottom orunderside 538 of the rigid panels 536 (specifically, theunderside 538 a-538 d off respective adjacent panels of 536 a-536 d as described herein) of thefolding cover assembly 530 as shown. In the preferred arrangements discussed herein, thehinges 544 are securely attached to the respectiverigid panels 536 and are sealed to prevent water or debris from entering the cargo box through thefolding cover assembly 530 at thehinges 544, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which atypical cargo box 5 would be exposed. - The support bows 550 are also schematically illustrated in
FIGS. 5A-5C . The support bows preferably include a bowmain portion 584 including a generally C-shaped channels with a bowupper portion 585 configured for attachment to thebottom surface 538 of therespective panel 536 and oriented with achannel opening 566 c at the bottom. The support bows 550 which are located at theflexible hinges 544 preferably include thehinge support flange flexible hinges 544 preferably also include theflange lip - As stated above, the support bows 550 are secured to the
respective panel 536. The support bows 550 are preferably located at thebottom surface 538 of therespective panel 536, and near thefront edge 541 b orrear edge 541 c of therespective panel 536. The support bows 550 are preferably secured to thebottom surface 538 of therespective panel 536 by an adhesive 570 b, which may include a layer or coating of adhesive or a double-sidedadhesive tape 571 b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows 550, to therespective panels 536. The double-sidedadhesive tape 571 b preferably includes anacrylic foam material 572 d withadhesive layer 572 e arranged on one side of theacrylic foam material 572 d and adhesive layer 572 f arranged on the other side of theacrylic foam material 572 d, for example. Preferably, the adhesive 570 b includes a double-sidedadhesive tape 571 b such as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sidedadhesive tape 571 b is an acrylic foam tape having anadhesive layer 572 e which includes pressure-sensitive adhesive and having an adhesive layer 572 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive, adhesive layer 572 f. Preferably, theadhesive layer 572 e (in this example, pressure-sensitive adhesive) is aligned with and adhered to theupper surface 566 d of thesupport bow 550 to adhere the double-sidedadhesive tape 571 b to thesupport bow 550; thesupport bow 550 together with the attached double-sidedadhesive tape 571 b is subsequently aligned with thepanel 536 and the release strip is removed. Preferably, the adhesive layer 572 f is then aligned with thepanel 536 and thesupport bow 550 is attached to therespective panel 536 by activating the adhesive layer 572 f (in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and theacrylic foam material FIG. 5A . Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles 559 are preferably also attached to the bottom surface orunderside 538 of therespective panels 536, preferably in a similar manner as that just described for thesupport bow 550. Although adhesive 570 b can be applied at selected portions of the length of thesupport bow 550 or thesidebar 559, adhesive 570 b is preferably applied along substantially the entire length of thesupport bow 550 and thesidebar 559, to enhance stability and to minimize unwanted vibrations. Alternatively, thesidebars 559 and support bows 550 can be attached to thepanels 536 with adhesives such as glue, or with fasteners, or spot welds. - In some apparatus and methods embodiments, the
folding cover assembly 530 folds in stages or steps; a preferred embodiment is schematically illustrated inFIG. 5D . In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly 530 (configuration 1), thehinge 544 a flexes to allow therear panel 536 a to fold up, passing through 90 degrees (configuration 2) towards themiddle panel 536 b, and fold over onto themiddle panel 536 b (configuration 3). Thehinge 544 b flexes to allow themiddle panel 536 b (together with therear panel 536 a which is folded onto themiddle panel 536 b) to fold up, passing through 90 degrees (configuration 4) towards thespacer panel 536 d, passing through a point at which standoffs 558 contact the front panel (configuration 5). Thehinge 544 b flexes back towards 90 degrees as thehinge 544 c flexes to allow thespacer panel 536 d to fold up, and continue to fold over (together with therear panel 536 a which is folded onto themiddle panel 536 b, and themiddle panel 536 b) towards thefront panel 536 c (configuration 6), until thefolding cover assembly 30 is folded up (configuration 7). Note thatFIG. 5D is a schematic overview of the general folding of thefolding cover assembly 530; the various configurations are further illustrated and described elsewhere herein in greater detail. - An alternate configuration of an alternate
folding cover assembly 530′ folded up is schematically illustrated inFIG. 5E . In some embodiments, thefront panel 536 c′ is noticeably longer thanpanels spacer panel 536 d is oriented approximately vertically when thefolding cover assembly 530 is folded up, and thefront panel 536 c simply extends farther frontward than themiddle panel 536 b and therear panel 536 a. In the example illustrated inFIG. 5E , thespacer panel 536 d is correspondingly longer to accommodate the lengths of thepanels spacer panel 536 d is noticeably non-vertical when thefolding cover assembly 530′ is folded up. The alternatefolding cover assembly 530′ also preferably includes correspondingflexible hinges standoffs 558. - Another alternate configuration of an alternate
folding cover assembly 530″ folded up is schematically illustrated inFIG. 5F , similar to the illustration ofFIG. 5E . In some embodiments, thefront panel 536 c″ is noticeably shorter thanpanels spacer panel 536 d is oriented approximately vertically when thefolding cover assembly 530 is folded up, and themiddle panel 536 b and therear panel 536 a simply extend farther frontward than thefront panel 536 c. In the example illustrated inFIG. 5F , thespacer panel 536 d is correspondingly longer to accommodate the lengths of thepanels folding cover assembly 530″ is folded up. The alternatefolding cover assembly 530″ also preferably includes correspondingflexible hinges standoffs 558. - In the examples illustrated in
FIGS. 5E and 5F , thespacer panel 536 d can be oriented preferably from about zero to about 60 degrees from a vertical orientation; the orientation is determined by the various lengths of thepanels 536 and astandoff distance 561 a (seeFIG. 14C ). When the cover assembly is in the fully folded position, thetop surface 537 d of thespacer panel 536 d can stand generally at an angle of from about 30 to about 150 degrees to thetop surface 537 c of thefront panel 536 c, preferably from about 40 to about 140 degrees to thetop surface 537 c of thefront panel 536 c; more preferably from about 50 to about 130 degrees to thetop surface 537 c of thefront panel 536 c; even more preferably from about 60 to about 120 degrees to thetop surface 537 c of thefront panel 536 c, and even more preferably from about 80 to about 100 degrees to thetop surface 537 c of thefront panel 536 c, generally depending upon the length of thefront panel 536 c, which can be varied in various embodiments of the cover assembly. In the preferred embodiment shown inFIG. 1 , thetop surface 537 d of thespacer panel 536 d will generally reside at an angle of about 90 degrees to thetop surface 537 c of thefront panel 536 c. - Referring now also to
FIGS. 20A-20B , thelength 539 a of therear panel 536 a is preferably somewhat smaller than thelength 539 b of themiddle panel 536 b so that therear panel 536 a does not interfere with thehinges support bow 550 e, or other nearby structures when thefolding cover assembly 530 is folded up or unfolded. If thelength 539 a of therear panel 536 a is too much smaller than thelength 539 b of themiddle panel 536 b, thestandoffs 558 attached to thesupport bow 550 a will be farther removed from the respective edges of thefront panel 536 c and themiddle panel 536 b and may not provide the desired support in the folded up configuration. More preferably, thelength 539 a of therear panel 536 a is from about 0.25 inch to about 8 inches smaller than thelength 539 b of themiddle panel 536 b. Still more preferably, thelength 539 a of therear panel 536 a is from about 0.5 inch to about 2 inches smaller than thelength 539 b of themiddle panel 536 b. Even more preferably, thelength 539 a of therear panel 536 a is about 0.75 inch smaller than thelength 539 b of themiddle panel 536 b. - Preferably, the
length 539 d of thespacer panel 536 d is large enough to accommodate thehinges support bow 550 e, but is preferably not significantly larger than required to accommodate thehinges support bow 550 e so that the stored profile of thefolding cover assembly 530 is minimized, and the folded profile when thefolding cover assembly 530 is folded up but remains attached to the side rails 520 a, 520 b as illustrated inFIG. 10D is minimized, which is believed to reduce any tendency for thefolding cover assembly 530 to catch wind when thefolding cover assembly 530 is folded up but remains attached to the side rails 520 a, 520 b and when thetruck 2 is in motion. In some embodiments, thelength 539 d of thespacer panel 536 d is no greater than about one-third thelengths respective panels - Preferably, the
length 539 b of themiddle panel 536 b is somewhat smaller than thelength 539 c of thefront panel 536 c so that the driver oroperator 8 can easily grasp the storage straps 543 a andstrap brackets 543 b, when thefolding cover assembly 530 is in the folded up configuration illustrated inFIG. 10A , to hook thestrap brackets 543 b in thebracket slots 543 c at the front of thefront panel 536 c as described below and illustrated inFIG. 10A-10D . If thelength 539 c of thefront panel 536 c is longer than thelength 539 b of themiddle panel 536 b, the folded up configuration of thefolding cover assembly 530, as illustrated inFIG. 10D , will cover a larger portion of thecargo box 5 so that there is a more limited opening to thecargo box 5 when thefolding cover assembly 530 is folded up and secured on thetruck 2 as illustrated inFIG. 10D . More preferably, thelength 539 b of themiddle panel 536 b is from about 0.25 inch to about 6 inches smaller than thelength 539 c of thefront panel 536 c. Still more preferably, thelength 539 b of themiddle panel 536 b is from about 1 inch to about 3 inches smaller than thelength 539 c of thefront panel 536 c. Even more preferably, thelength 539 b of themiddle panel 536 b is about 1.733 inches smaller than thelength 539 c of thefront panel 536 c. - Once the latches 552 at both ends of the
support bow 550 a are retracted as shown inFIGS. 4A and 4B and described above, the rear end of therear panel 536 a can be lifted up from bothside rails hinge 544 a as illustrated inFIGS. 6A and 6B . As therear panel 536 a is lifted up, hooks 562 at the ends of thesupport bow 550 at the front of therear panel 536 a disengage from the respective catches 564; specifically, hook 562 a disengages fromcatch 564 a attached toside rail 520 a, and hook 562 b disengages fromcatch 564 b attached toside rail 520 b. The structure and function of the hooks 562 and catches 564 are described in further detail elsewhere herein (see, for example,FIG. 19A ). - The
rear panel 536 a is rotated further, onto themiddle panel 536 b as illustrated inFIGS. 7A and 7B . At this point, themiddle panel 536 b can be lifted from the side rails 520 a and 520 b, with themiddle panel 536 b (together with therear panel 536 a which is folded onto themiddle panel 536 b) pivoting upwards and frontwards, bending thehinge 544 b. A portion of thefolding cover assembly 530 in schematic cross section view similar to the views ofFIGS. 5A and 5B is illustrated inFIG. 7A , which shows thehinge 544 a folded in the configuration ofFIGS. 7A and 7B . - With lifting and rotating of the
middle panel 536 b together with therear panel 536 a until themiddle panel 536 b is approximately vertical, the configuration is as depicted inFIG. 8A-8B . With continued lifting and rotating of themiddle panel 536 b frontwards, themiddle panel 536 b together with therear panel 536 a rotates frontwards towards thefront panel 536 c. Preferably, thefolding cover assembly 530 includesstandoffs 558, located on theunderside 538 a of therear panel 536 c. Thestandoffs 558 can be attached to the bottom side of therear panel 536 a or attached to other structures such as support bows 550 or handles 559; in the example illustrated inFIGS. 8A-8E , there are fourstandoffs 558, two of which are attached to each of two sidebars or handles 559 on theunderside 538 a of therear panel 536 c. Thestandoffs 558 are preferably located so that two are proximate thefront edge 541 b of therear panel 536 a, and two are proximate therear edge 541 c of therear panel 536 a. Thestandoffs 558, and a preferred attachment of thestandoffs 558 to thehandles 559, are described further below, including with reference toFIGS. 14A-14C . Through the folding and rotating of themiddle panel 536 b and therear panel 536 a as just described, thestandoffs 558 proximate therear edge 541 c of therear panel 536 a contact thetop surface 537 c of the front panel 36 c as shown inFIG. 8C . Thestandoffs 558 help to maintain a spaced relationship between therear panel 536 a and thefront panel 536 c. With continued rotating of themiddle panel 536 b (together with thefront panel 536 a) thehinge 544 c bends and thespacer panel 536 d lifts off the side rails 520 a and 520 b as illustrated inFIG. 8D . With continued rotating of themiddle panel 536 b frontwards, together with therear panel 536 a and thespacer panel 536 d, and pivoting and sliding of thestandoffs 558, themiddle panel 536 b, therear panel 536 a, and thespacer panel 536 d rotate progressively farther frontwards towards thefront panel 536 c, as illustrated inFIGS. 8E , until thestandoffs 558 all contact thefront panel 536 c (FIG. 9A ). During this folding of thefolding cover assembly 530, thehinges middle panel 536 b, therear panel 536 a, and thespacer panel 536 d rotate towards thefront panel 536 c as schematically illustrated inFIGS. 8F and 10E . Depending on forces applied by the driver orother operator 8, thehinges FIGS. 8A, 8C-8E, and 10D , during the folding up of thefolding cover assembly 530, the angle A between themiddle panel 536 b and thespacer panel 536 d (which is about 180 degrees before beginning the folding up of themiddle panel 536 b onto thefront panel 536 c, as in the configuration illustrated inFIG. 7A ) initially decreases to angle A1 which is about 90 degrees as shown inFIG. 8A , then decreases past 90 degrees to angle A2 at which point thestandoffs 558 contact thetop surface 537 c of thefront panel 536 c as shown inFIG. 8C ; angle A2 may be about 35 degrees, but may be somewhat larger or smaller than about 35 degrees depending on thestandoff distance 561 a (FIG. 14C ) and asetback distance 561 b (FIG. 10D ) between thestandoff 558 proximate therear edge 541 c of therear panel 536 a and therear edge 541 c of therear panel 536 a, and also depending on therelative lengths rear panel 536 a and themiddle panel 536 b, respectively. Angle B between thespacer panel 536 d and thefront panel 536 c (which is about 180 degrees before beginning the folding up of thefolding cover assembly 530, as in the configuration illustrated inFIG. 7A ) is shown as angle B1 in the configuration ofFIG. 8A as about 180 degrees, and is shown as angle B2 in the configuration ofFIG. 8C , preferably remaining at about 180 degrees until thestandoffs 558 contact thetop surface 537 c of thefront panel 536 c as shown inFIG. 8C . Angle C between therear panel 536 b and thefront panel 536 c (which is about 180 degrees before beginning the folding up of thefolding cover assembly 530, as in the configuration illustrated inFIG. 7A ) initially decreases to angle C1 which is about 90 degrees as shown inFIG. 8A , then decreases past 90 degrees to angle C2 at which point thestandoffs 558 contact thetop surface 537 c of thefront panel 536 c as shown inFIG. 8C . With continued rotation of therear panel 536 a andmiddle panel 536 b andspacer panel 536 d, depending on the forces and manipulations applied by the driver oroperator 8, the angle A may remain about the same or may increase again as the angle B begins to decrease and the angle C continues to decrease, as shown as angles A3, B3, and C3 inFIG. 8D . With still continued rotation of therear panel 536 a andmiddle panel 536 b andspacer panel 536 d, the angles A and B continue to approach about 90 degrees as the angle C continues to approach zero degrees as shown as angles A4, B4, and C4 inFIG. 8E . When thefolding cover assembly 530 is completely folded, the angles A and B are preferably about 90 degrees and the angle C is preferably about zero degrees, as shown as angles A5, B5 and C5 inFIG. 10D , with therear panel 536 a, themiddle panel 536 b, and thefront panel 536 c being approximately parallel to each other, and thespacer panel 536 d approximately vertical, oriented at about 90 degrees with respect to thepanels - As the
folding cover assembly 530 is folded up, the angle C between therear panel 536 a and thefront panel 536 c decreases towards about zero degrees, passing through the configurations depicted inFIGS. 8C-8E . For embodiments in which the folded configuration of thefolding cover assembly 530 has therear panel 536 a folded so that it is parallel to thefront panel 536 c, the approximate relationship between the angles A, B, and C is believed to be given by the equation (angle C)=(angle A)+(angle B)— (180 degrees). - At this point, as illustrated in
FIGS. 9A, 9B, and 10A , thefolding cover assembly 530 is folded up, but is still attached to the side rails 520 a and 520 b, with thelatches support bow 550 f) engaged with theside rail lip 524 of the side rails 520 a and 520 b, respectively, and thehooks support bow 550 g engaged with thecatches FIGS. 10C-11A . Preferably, the containment bracket oranchor socket 525 a is affixed to theside rail 520 a (see for exampleFIGS. 2E and 9B ), and a mirror-image anchor socket 525 b is affixed toside rail 520 b (see for exampleFIG. 11A ). The anchor sockets orcontainment brackets engaging portion 553 b of the latches 552 proximate each end of thesupport bow 550 g in a desired location along theside rail lip 524 of the side rails 520 a and 520 b and thereby aid in positioning thefolding cover assembly 530 in a desired alignment with respect to thecargo box 5 when the engagingportion 553 b of the latches 552 at each end of thesupport bow 550 g are engaged with theside rail lip 524 of the side rails 520 a and 520 b. - Referring now to
FIGS. 10A-10D , bundling means such as bungee cords orstorage straps 543 a can be utilized to fix thefolding cover assembly 530 in the folded configuration; other straps, buckles, or hooks can be utilized as bundling means.FIGS. 10A-10D show a preferred embodiment, in which two elastic storage straps 543 a are provided, one towards either side of themiddle panel 536 b, for securing thefolding cover assembly 530 in a folded configuration. Preferably,strap brackets 543 b are provided for eachstorage strap 543 a, for hooking the storage straps 543 a to thefront panel 536 c; thestrap brackets 543 b are preferably formed of a strong polymer such as a polyamide, although other materials, including composites and metals, can be used. More preferably, thestrap brackets 543 b are formed of nylon. Preferably,bracket slots 543 c are provided in thefront panel 536 c, and accommodate thestrap brackets 543 b. Thestrap brackets 543 b are attached to or captured on the storage straps 543 a, and thestrap brackets 543 b hook to thebracket slots 543 c in thefront panel 536 c to secure thefolding cover assembly 530 in the folded configuration when desired. In the front perspective view ofFIG. 10B of the foldedfolding cover assembly 530, astorage strap 543 a is hooked to thefront panel 536 c with astrap bracket 543 b. Also illustrated onFIG. 10B are support bows including support bows 550 b, 550 c, 550 d, and 550 g, swing latches 562 b, 562 d, and 562 f,standoff 558,protective pad 558 a, andprotective film 574.FIG. 10C is a front view which illustrates astorage strap 543 a near each side of themiddle panel 536 b which is hooked to thefront panel 536 c withcorresponding strap brackets 543 b to secure the foldedfolding cover assembly 530 in a folded configuration as shown.FIG. 10D shows a side view of this folded configuration of thefolding cover assembly 530, with therear panel 536 a secured to thefront panel 536 c. Thefolding cover assembly 530 can be left in this folded configuration, as illustrated inFIG. 10D , covering only the front portion of thecargo box 5. - The protective film(s) 574 is preferably located on the
top surface 537 c of thefront panel 536 c so that theprotective film 574 is aligned with therespective standoff 558 as illustrated inFIGS. 9A, 10, and 10B , which illustrate the foldingtonneau cover assembly 530 folded up. When theprotective film 574 is located as shown between thestandoff 558 and thetop surface 537 c of thefront panel 536 c, damage to thetop surface 537 c by contact and abrasion by theprotective pad 558 a is minimized. When traveling, the foldingtonneau cover assembly 530 may be in the folded up configuration such as illustrated inFIG. 10B , with thestrap bracket 543 b of eachstorage strap 543 a engaged with thebracket slot 543 c as illustrated. - The
folding cover assembly 530, folded up and bundled and left secured to the side rails 520 a and 520 b in the configuration ofFIGS. 10B-10D is illustrated in a rear perspective view, viewed from slightly below and to the driver's side of the folding tonneau cover apparatus inFIG. 11A . As state above, the cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b; the clip cord guides 555 a and retainer cord guides 555 b are further illustrated inFIG. 11B . The truck can be driven with thefolding cover assembly 530 in this folded up configuration if desired. - Alternatively, if it is desired to remove the
folding cover assembly 530 to leave thecargo box 5 completely uncovered, thefolding cover assembly 530 can be removed as follows. As illustrated inFIG. 11A therelease cord 554 b is accessible and can easily be grasped by a driver orother operator 8. Pulling on therelease cord 554 b will retract the latches 552 at the ends of thesupport bow 550 f against the force of the biasing members or springs 556, similar to the way in which pulling on therelease cord 554 a retracts the latches 552 at the ends of thesupport bow 550 a as illustrated inFIG. 4B . Typically, therelease cord 554 b will be pulled by a driver orother operator 8; theoperator 8 preferably has entered thecargo box 5 via thetailgate 6 d to grasp therelease cord 554 b. When therelease cord 554 b is pulled, the engagingportions 553 b of the latches 552 at the ends ofsupport bow 550 f are retracted away from the lipsside rail lips 524 of the side rails 520 a and 520 b, releasing the latches 552 from the side rails 520 a and 520 b, and allowing the rear portion of thefront panel 536 c to be lifted up from the side rails 20 a and 20 b and rotated to disengage thehooks catches folding cover assembly 530 is free from the side rails 520 a and 520 b of thesupport frame assembly 518 and can be lifted up and off thecargo box 5 as illustrated inFIG. 12 ; thefolding cover assembly 530 can be moved away from thepickup truck 2, or stowed in thecargo box 5 or elsewhere as desired. In this case, thetop opening 6 f of thecargo box 5 is not partially covered by the folded up foldingcover assembly 530. - When it is desired to replace the
folding cover assembly 30 on thecargo box 5, or to close one or more panels 36, the various steps illustrated can be done in the reverse order, as described in further detail below in reference toFIG. 19C . To latch the various latches 552, however, it is not necessary to manually retract any of the release cords 554, since thelatch slide 553 has aninclined bottom surface 553 a. When thelatch slide 553 contacts and is forced further towards theside rail lip 524 of the side rails 520 a or 520 b, theinclined bottom surface 553 a of thelatch slide 553 will retract the engagingportion 553 b to allow theengaging portion 553 b to move past theside rail lip 524, whereupon thespring 556 will move the engagingportion 553 b into the secured configuration, such as illustrated inFIG. 3B and elsewhere herein. - Referring now to
FIGS. 13A-13D , the cord guides 555 are schematically illustrated. As stated above, the cord guides 555 preferably include clip cord guides 555 a and retainer cord guides 555 b. Eachclip cord guide 555 a is preferably attached to asupport bow 550 as illustrated inFIGS. 13A-13C . Theclip cord guide 555 a preferably has a securement feature orsecurement portion 560 a which is configured for attachment to thesupport bow 550. The securement feature 650 a is preferably oblong and is narrow enough to fit into thechannel opening 566 c, and when aligned with the open bottom of thebow bottom portion 566 b as illustrated inFIG. 13A , thesecurement feature 650 a can be inserted into thesupport bow 550 as shown inFIG. 13B . Theclip cord guide 555 a is then rotated as indicated by the arrow onFIG. 13B so that thesecurement feature 650 a secures theclip cord guide 555 a to thesupport bow 550 as shown inFIG. 13C . Eachretainer cord guide 555 b is preferably inserted into the open end of thesupport bow 550 and slid along thesupport bow 550 to a desired location. The release cord 554 passes between theretainer cord guide 555 b and thesupport bow 550 as schematically illustrated inFIG. 13D so that theretainer cord guide 555 b retains the release cord 554. The combination of clip cord guide(s) 555 a and retainer cord guide(s) 555 b keep the respective release cord positioned in alignment with the latches 552 and adjacent to or within therespective support bow 550. Note that in the schematic illustrations ofFIGS. 13A-13D , some elements are not shown, such as the adhesive 570 b (which may includeadhesive tape 571 b),hinge 544, hingesupport flange 586, and so forth, in order to highlight the particular features being described. The elements shown in the schematic illustrations ofFIGS. 13A-13D are not necessarily drawn to scale. - Referring now to
FIGS. 14A-14C , attachment of astandoff 558 to a sidebar or handle 559 is illustrated. Thestandoff 558 preferably has asecurement portion 560 b which is configured for attachment to the sidebar or handle 559. Preferably, thesecurement portion 560 b preferably includes twolongitudinal grooves handle 559. Thestandoff 558 preferably includes anelongated projection 558 d which can be grasped to snap thestandoff 558 onto thehandle 559 or to remove thestandoff 558 from thehandle 559. Further, theelongated projection 558 d is preferably angled to aid in guiding thestandoff 558 into engagement with thehandle 559. Preferably, thelongitudinal groove 558 b is hooked onto thehandle 559 as illustrated inFIG. 14B , and theelongated projection 558 d is used to aid in hooking thelongitudinal groove 558 c onto thehandle 559 to secure thestandoff 558 on thehandle 559 as illustrated inFIG. 14C . The dimensions of thestandoff 558 and position of thestandoff 558, including thestandoff distance 561 a and thesetback distance 561 b (FIG. 10D ) when secured to thehandle 559 together determine the angle C2 (FIG. 8C ) at which thestandoff 558 contacts thefront panel 536 c when thefolding cover assembly 530 is being folded up. Preferably, a protective pad or insert orrubber foot 558 a is attached to the end of thestandoff 558 as shown; theprotective pad 558 a preferably secures to thestandoff 558 by adhesive such as those described herein or other adhesive known in the art. Theprotective pad 558 a serves to reduce impact or abrasion damage to thefront panel 536 c when thefolding cover assembly 530 is folded up onto thefront panel 536 c. - In this example, the
length 539 d of thespacer panel 536 d is substantially smaller than thelengths other panels FIG. 2A ). The dimensions of thestandoff 558 are chosen to accommodate thelength 539 d of thespacer panel 536 d, so that thefront panel 536 a and therear panel 536 c are preferably parallel and separated from one another in the folded configuration such as is illustrated inFIG. 10D . Thelarger lengths panels cargo box 5, while thesmaller length 539 d of thespacer panel 536 d provides for folding up of thefolding cover assembly 530 to a convenient folded size, while providing space for thevarious hinges 544, support bows 550, and other components within the folded-upfolding cover assembly 530. As thespacer panel 536 d, themiddle panel 536 b, and therear panel 536 a are folded together onto thefront panel 536 c, thestandoff 558 the rear end of each of thehandles 559 attached to thebottom surface 538 a of therear panel 536 a contacts thefront panel 536 c and provides a pivot point and sliding support to aid in orienting thepanels 536 in the folded configuration as shown. Preferably, thestandoff 558 is long enough to ensure contact between theprotective pad 558 a and thetop surface 537 c of thepanel 536 c in order to minimize movement and stress on thehinges protective pad 558 a and thetop surface 537 c of thepanel 536 c. Preferably, thestandoff 558 is short enough to avoid undue stress on thepanel 536 c and thehinges folding cover assembly 530 is folded up as illustrated inFIGS. 10A-10D . - Referring to
FIGS. 15A-15C , theperimeter seal 534 provides a seal against the entry of water, dust, or other debris into thecargo box 5 around the perimeter of thefolding cover assembly 530. Theperimeter seal 534 can also adapt to irregularities in the fit between thefolding cover assembly 530 and thesidewalls front wall 6 c, andtailgate 6 d of thecargo box 5. Theperimeter seal 534 is preferably attached to thepanels 536 with adhesive such as adhesive 570 a, 570 b described above, although other attachment mechanisms can be used to secure theperimeter seal 534 to theunderside 538 of therespective panel 536, such as those described herein for attachment of theflexible hinge 544 or the support bows 550 or thehandle 559 to thepanels 536.FIG. 15A schematically illustrates one example perimeter seal 534 a having D-shaped cross section as shown. Preferably, adhesive 535 is used to secure theperimeter seal 534 to thepanels 536; although other types of adhesive, such as pressure-activated, heat-activated, UV-activated, chemical-reaction-cure, or other adhesives that are known in the art, can be used, preferably adhesive 535 is an adhesive such as the previously describedadhesives FIG. 15B schematically illustrates anotherexample perimeter seal 534 b having aperimeter seal lip 534 d;perimeter seal lip 534 d can aid in alignment of theperimeter seal 534 at the edge of thepanel 536, and can also provide some protection when manipulatingpanel 536 so that injury from contact with any narrow or sharp edges of thepanel 536 is avoided.FIG. 15C schematically illustrates anotherexample perimeter seal 534 c having an extendedperimeter seal flange 534 e which provides similar advantages as theperimeter seal lip 534 d but also extends a short distance over the top surface of thepanel 536; theexample perimeter seal 534 c has an open cross section with anextended sealing feature 534 f. Different configurations of theperimeter seal 534 can be used in different portions of thefolding cover assembly 530. For example, the perimeter seal 534 a could be used along the front of thefront panel 536 c to seal against thefront wall 6 c of thecargo box 5, while theperimeter seal 534 b could be used along the sides of thepanels 536 to seal against thesidewalls sidewall cap 6 e, if thetruck 2 is so equipped), while theperimeter seal 534 c could be used along the rear of therear panel 536 a to seal against thetailgate 6 d. Further example perimeter seals includeperimeter seal 534 g, schematically illustrated inFIG. 15D , which has an open cross section similar toperimeter seal 534 c but without an extended lip or flange.FIG. 15E illustrates anexample perimeter seal 534 h which is similar toperimeter seal 534 b but also includes an extended perimeter seal flange similar to that shown inFIG. 15C .FIG. 15F shows an edge guard 534 i for attachment at an exposed edge of apanel 536 but with minimal intrusion along the top surface 537 or the bottom surface orunderside 538 of the respective panel 536 (corresponding to thetop surface 532 a or thebottom surface 532 b, respectively, of the folding cover assembly 530); edge guard 534 i can be used for protection at the rear edge of therear panel 536 a, for example. Edge guard 534 i is preferably secured by an interference fit with therespective panel 536; alternatively, edge guard 534 i can be secured to therespective panel 536 by an adhesive such as adhesive 535 illustrated inFIGS. 15A-15E, 15G-15H .FIG. 15G schematically illustrates aperimeter seal 534 j similar to perimeter seal 534 g ofFIG. 15D but having anextended sealing feature 534 f somewhat shorter than the perimeter seal ofFIG. 15D , as shown. Apreferred perimeter seal 534 k is schematically illustrated inFIG. 15H . Theperimeter seal 534 k preferably includes extendedsealing feature 534 f and a thick back portion 534 m, with the adhesive 535 located at the thick back portion 534 m for securing theperimeter seal 534 k to the respective panel(s) 536. Theperimeter seal 534 can be formed into a bend at the corners of thecargo box 5, or separate segments of theperimeter seal 534 can be applied near each of the driver's side, passenger side, front side, and rear side of thefolding cover apparatus 530, preferably cut to meet at a 45 degree angle to provide an essentially continuous perimeter seal around the perimeter. In a similar manner, differing configurations ofperimeter seal 534, such as various perimeter seals 534 a, 534 b, 534 c, 534 g, 534 h, 534 j, and 534 k described herein can be used along different portions of the perimeter, preferably cut to meet in close approximation and thereby providing an essentially continuous perimeter seal around the perimeter but with differing seal configurations at different portions of the perimeter. An edge guard such as edge guard 534 i can be used to protect against damage or injury from the edge of thepanel 536. Preferably, theperimeter seal 534 is arranged to provide an essentially continuous seal around the perimeter of thecargo box 5, and in addition, the rear edge of therear panel 536 a preferably has an edge guard 534 i. Thus, some portions of thefolding cover assembly 530 have perimeter seals 534 (which may include perimeter seals 534 a, 534 b, 534 c, 534 g, 534 h, 534 j, 534 k, for example) in addition to edge guard 534 i. Alternatively, the extendedperimeter seal flange 534 e can be incorporated into theperimeter seal 534 so that a separate edge guard 534 i is not required. Various perimeter seals and edge guards made of polymeric material, as shown inFIGS. 15A-15H , are available from Lakeview Industries, Chaska, Minn. Preferably, thefolding cover assembly 530 described herein includes a perimeter seal such as a perimeter seal disclosed herein, such asperimeter seal folding cover assembly 530 preferably includes the perimeter seal 534 a along each of thesidewalls perimeter seal 534 k along thefront wall 6 c, and theperimeter seal 534 h along the rear portion (proximate thetailgate 6 d). - The
panels 536 preferably include sheet metal, although a rigid and tough polymer sheet can be used. In particular, lightweight and strong metal alloys, such as aluminum alloys, are preferred. Thepanels 536 are preferably relatively rigid as compared to thehinges 544, so that when thefolding cover assembly 530 is folded up as described herein, thepanels 536 remain relatively flat, while thehinges 544 can flex to fold up thefolding cover assembly 530. Preferably, thepanels 536 are from about 0.020 inches to about 0.200 inches thick. More preferably, the panel material is 5052-T34 rolled aluminum alloy from Aleris Inc., Cleveland, Ohio, which has a thickness of about 0.063 inches thick and is coated on the top with a Krystal Kote™ polyester paint system coating from Valspar Sourcing, Inc., Minneapolis, Minn. and on the bottom with a clear epoxy coating while it is in the factory. The rolled aluminum alloy is manufactured into a coil of rolled aluminum. Once cooled, the coil is unrolled and separately coated on the top and the bottom surfaces of the aluminum material, heat treated and recoiled for delivery to a material handler or to the buyer. The coated panel material is then unrolled and panels are cut using a laser cutting machine or such other equipment that allows the panels to be effectively cut to desired size and shape specifications. The thickness of the respective panels is minimized to limit the weight of the respective panels and the cost of the materials, but it the panels are too thin they will be subject to deformation between supporting structures. The panel material will preferably have a thickness of from about 0.020 inches to about 0.200 inches, more preferably from about 0.030 inches to about 0.126 inches, still more preferably from about 0.040 inches to about 0.100 inches, even more preferably from about 0.050 inches to about 0.080 inches, and most preferably about 0.063 inches. Other protective coatings can be used, such as urethane coatings, which may include UV protection. Protective coatings may be obtained, for example, from BASF (Wyandotte, Mich.) and Glasteel (Moscow, Tenn.). One preferred protective coating is BASF Elastocoat R85A92 WHT. Other rigid panels such as fiber reinforced plastic panels, such as can be obtained from Polser FRP Panels, Inc. (Izmir, Turkey). - This most preferred thickness was selected for a number of reasons including strength and process limitations. For the preferred coating described above, 0.063 inches is the thickest size that is believed to be presently available from manufacturers of the product. Since this was the thickest material that could be obtained with the preferred coating, the rigid alloy 5052-T34 with the aforementioned coatings was selected from a number of other materials having a number of other sizes. The inventors have determined that using an aluminum alloy allows the cover to be both light weight and rigid. The 5052-T34 material was chosen because it allows the cover to be strong and resistant to permanent deflections under static loads, denting, bending and long term abuse. The thickness also creates limitations if it is too thick because the
panels 536 may interfere with one another at the hinge locations when thefolding tonneau cover 530 is folded up and can therefore add a lot of unwanted stress on the hingeflexible hinge body 545 a or the adhesive 570 a, 571 a where the respective hinges 544 are attached and sealed to theadjacent panels 536. If the panel material is too thin, thepanels 536 will sag and easily deform with static loads. In alternate embodiments, other materials are used to make thepanels 536 such as steel, aluminum, fiberglass, carbon fiber, ceramic, thermoset plastics, thermoplastics, HDPE, LDPE, ABS, PVC, Nylon, titanium alloy, magnesium alloy, copper, brass, stainless steel, rubber, fiber-reinforced or glass-containing polymeric materials and the like. - As noted, the preferred coatings on the
panels 536 are a Kyrstal Kote™ polyester paint system from Valspar, preferably a black polyester base coat with a clear texture top coat on the top surface 537 and a clear epoxy coating on the underside orbottom surface 538 of thepanels 536. Other coatings that could be used in alternate embodiments include acrylic paints, polyester paints, epoxy coatings, galvanized coatings, zinc plating, anodizing, other plating systems and the like. Alternative coatings include any combination of the above-mentioned coatings on either the top or the bottom sides of thepanels 536. The texture on the top surface 537,bottom surface 538 of therespective panels 536 can be smooth, brushed, embossed, dented, sandblasted, rolled, waved and the like. Although a black top surface is preferred on thepanels 536, coating including others colors that are well known in the art may also be applied on the top surfaces 537 and the bottom surfaces 538 of therespective panels 536 in alternative embodiments. It will be appreciated that the coating on the respective surfaces are desirable both aesthetically and functionally to enable the respective surfaces to hold up over time in harsh environments. - Now referring also to
FIGS. 16A-16K , the support bows 550 are preferably metal channels, more preferably extruded aluminum, although a strong thermoplastic or other polymeric material that is either molded or extruded could be used. Preferably, the support bows 550 b-550 f have a slight bend or bow, and are curved so that they are downwardly concave or concave down as shown (deflection distance d is exaggerated in some views for clarity of illustration). When thepanels 536 are attached to the bent support bows 550 b-550 f, thepanels 536 deflect and take on a corresponding slight bend or bow, except for the rear portion of therear panel 536 a and the front portion of thefront panel 536 c, which are preferably flat so that they approximate the shape of thetailgate 6 d and thefront wall 6 c of thecargo box 5. For this reason, the support bows 550 a and 550 g are preferably straight. The resulting slight bow in thefolding cover assembly 530 aids in shedding of water or debris from thefolding cover assembly 530. Although the support bows 550 preferably include extruded channel, as long as theupper surface 566 d of thesupport bow 550 has this downward curvature, the curvature will be imposed upon thepanels 536 in the manner described. Anexample support bow 550 which is straight is schematically illustrated inFIG. 16A ; thesupport bow 550 a at the rear of therear panel 536 a and support bow 550 g at the front of thefront panel 536 c are preferably straight. Support bows 550 which are curved or bent are schematically illustrated inFIGS. 16B, 16C, 16E, 16G, 16I, and 16K ; the support bows 550 b, 550 c, 550 d, 550 e, and 550 f are preferably curved. Such curved support bows 550 are referenced as 550′ inFIGS. 16B, 16C, and 16E, 550 a′ inFIG. 16G, 550 d′, 550 f′ inFIG. 16I, and 550 e′ inFIG. 16K , to distinguish them from the straight support bows 550, 550 a, 550 d, 550 f, and 550 e, respectively, inFIGS. 16A, 16F, and 16H, and 16J . Theupper surface 566 d of eachrespective support bow 550′, 550 a′, 550 d′, 550 f′ is preferably curved so that theupper surface 566 d at the ends of therespective support bow 550 are a deflection distance d lower than a highest extent of theupper surface 566 d of thesupport bow 550 as shown (between the ends of thesupport bow 550, but preferably at the center portion of thesupport bow 550 as shown inFIG. 16B ). The deflection distance d is preferably between about zero and about 1 inch; more preferably, the deflection distance d is preferably between about 1/64th inch and about ½ inch; still more preferably, the deflection distance d is about ⅛ inch. These example approximate deflection distances are for atypical cargo box 5 of atypical pickup truck 2; for wider or narrower cargo boxes, the length of therespective panels 536 and the respective support bows 50 may be longer or shorter, and the deflection distance d is preferably correspondingly larger or smaller, in order to provide a similar function in aiding the run-off of water or other debris from thepanels 536. Currently, for example, most common pickup truck cargo boxes are from about 3.5 feet to about 6 feet in width; the deflection distance is preferably correspondingly smaller or larger when the folding cover assembly is sized to cover a cargo box which is narrower than about 3.5 feet or wider than about 6 feet, respectively. The inventors have found that for most common trucks, a deflection distance d which is about 1/16 inch or less typically does not provide the preferred water run-off. The inventors have also found that a deflection distance d which is about 3/16 inch or more can create unwanted stress particularly in thepanels curved support bow 550 and one generallystraight support bow 550 configured to approximate the shape of thetailgate 6 d and thefront wall 6 c of thecargo box 5. Therefore, we have found that for the typicaltruck cargo boxes 5 about 3.5 to about 6 feet in width, the preferred deflection distance is between about 1/16 inch and 3/16 inch. In some embodiments, support bows 550 include optional opposed support holes 574 e in the front and rear portions of the support bow as illustrated. -
Support bow 550 e is shown inFIG. 16J , which also illustrates bowmain portion 584, bowupper portion 585, hingesupport flange 586, andflange lips curved support bow 550 e′ is shown inFIG. 16K , which also illustrates bowmain portion 584′, bowupper portion 585′, hingesupport flanges 586 a′ and 586 b′, andflange lips 587 a′ and 587 b′. - In preferred embodiments, the support bows 550 include the bow
main portion 584 including a generally C-shaped channel with the bowupper portion 585 configured for attachment to thebottom surface 538 of therespective panel 536 and oriented with thechannel opening 566 c at the bottom. Some components of the foldingtonneau cover apparatus 510 preferably slide into or are attached to the support bows 550, including the latch slides 553, the cord guides 555, thestandoffs 558,spring 556, and thespring retainers 557 a. Thebow end caps 565 preferably slide into the ends of the support bows 550. - Some embodiments include support bows 550 that are straight, such as the support bows 550 that are schematically illustrated in
FIGS. 16F, 16H, and 16J , which include nohinge support flange hinge support flange 586 a, 685 b, or twohinge support flanges FIGS. 16G, 16I and 16K, which include nohinge support flange hinge support flange 586 a, 685 b, or twohinge support flanges folding cover assembly 530 preferably includes support bows 550 that are straight as support bows 550 a and 550 g illustrated inFIGS. 2B, 16A, and 16F ; support bows 550 a and 550 g are not adjacent to ahinge 544 and therefore do not require ahinge support flange FIGS. 16A, 16F ). Thefolding cover assembly 530 preferably includes support bows 550 that are curved or bent (concave down) and include ahinge support flange 586 a located to one side of the bowmain portion 584 and extending to support thehinge side portion FIGS. 16H and 16I . Thefolding cover assembly 530 more preferably includes support bows 550 that are bent and have ahinge support flange 586 a as support bows 550 b, 550 c, 550 d and 550 f (FIG. 2B ). Preferably, thefolding cover assembly 530 includes asupport bow 550 that includes twohinge support flanges main portion 584, eachhinge support flange hinge side portion hinge FIGS. 16J and 16K . Thefolding cover assembly 530 more preferably includes asupport bow 550 that is bent and has two hinge support flanges assupport bow 550 e (FIGS. 2B, 16K ). - The sidebars or handles 559 are attached to
panels panel 536. Thesidebars 559 provide additional support along the side portions of thepanels 536. Thesidebars 559 are preferably metal, although a strong polymer can be used. More preferably, thesidebars 559 are formed of aluminum. Thesidebars 559 are preferably formed with recesses or other grasping features, to facilitate grasping for lifting and positioning thepanels 536 during opening and closing of thefolding cover assembly 530. Preferably, the support bows 550 and the sidebars or handles 559 are elongated, so that they can provide support across thewidth 540 orlength 539, respectively, of therespective panel 536. - Referring now to
FIGS. 17A-17B , viewed along theviewing line 17A-17A inFIG. 3A , additional details in the vicinity of the side of thespacer panel 536 d are illustrated. These views show hinges 544 b and 544 c, latch 552 d, and support bows 550 d, 550 e, 550 f, and thecontainment bracket 525 b. InFIG. 17B , themiddle panel 536 b has been raised up to begin folding this portion of thefolding cover assembly 530. Thehinge 544 b is shown flexing, and thehook 562 d is rotated and displaced from thecatch 564 d so that thespacer panel 536 d can also be lifted up. Some elements shown elsewhere herein are not shown inFIGS. 17A and/or 17B to show the hinge function more clearly. - The
hinge body 545 a is further illustrated inFIG. 17C , which is an isolated perspective view of thehinge body 545 a and the adhesive 570 a, illustrating the hingelongitudinal axis 545 b, thehinge body profile 545 c along a representative vertical front-rear section plane 597, the hinge bodyupper surface 595, the hinge bodylower surface 596,representative hinge thickness 545 d in two locations, thecentral portion 546 a, theside portions intermediate portions - As described above in relation to the schematic illustrations in
FIGS. 5A-5B , theflexible hinge body 545 a preferably includes more than one polymeric material such as those described herein; for example, theflexible hinge body 545 a may include a softer or lower-durometerelastomeric polymer material 547 c and a harder or higher-durometerelastomeric polymer material 547 d. Thecentral portion 546 a preferably includes the softerelastomeric polymer material 547 c, and theside portions rigid panels 536 as stated, preferably include the harderelastomeric polymer material 547 d. In such embodiments, a transition or mixing of the materials preferably occurs in theintermediate portions central portion 546 a being more flexible in bending than theintermediate portions side portions flexible hinge body 545 a preferentially occurs in thecentral portion 546 a, although some flexing and bending can occur in other portions of theflexible hinge 544 in addition to the central portion. Embodiments of thehinge 544 a are further illustrated inFIGS. 18A-18F , which are schematic illustrations similar to those ofFIGS. 5A and 5B , with similar orientation as viewed fromline 5A-5A onFIG. 2A . - A portion of the
hinge body 545 a is shown in a perspective view inFIG. 17D taken from the dashedrectangle 17D shown inFIG. 17C , which shows thehinge body profile 545 c of thehinge body 545 a, and also showing thecentral portion 546 a, theside portions intermediate portions flexible polymer material 547 c,stiffer polymer material 547 d, intermediate polymer material 547 e, adhesive 570 a and 570 b, hinge bodyupper surface 595, and hinge bodylower surface 596. - A portion of the
hinge body 545 a′ is shown in perspective view inFIG. 17E which is similar to the view shown inFIG. 17D , except that the hinge body that is shown is analternate hinge body 545 a′, which shows thehinge body profile 545 c′ of thehinge body 545 a′, and also showing thecentral portion 546 a′, theside portions 546 b′ and 546 c′, theintermediate portions 546 d′ and 546 e′, hingebody polymer material 547 a′, and double-sidedadhesive tape 571 a. A portion of thehinge body 545 a′″ is shown in perspective view inFIG. 17F which is similar to the view shown inFIG. 17D , except that the hinge body that is shown is an alternate hinge body 545′″, which shows thehinge body profile 545 c′″ of thehinge body 545 a′″, and also showing thecentral portion 546 a′″, theside portions 546 b′″ and 546 c′″, theintermediate portions 546 d′″ and 546 e′″, hingebody polymer material 547 a′, and double-sidedadhesive tape 571 a. - A portion of the
hinge body profile 545 c′″ ofhinge body 545 a′″ is shown inFIG. 17G , in an enlarged schematic illustration similar to that shown inFIG. 18J , which is referenced herein below, except that thehinge body 545 a, shown inFIG. 18J , is somewhat different from that of thehinge body 545 a′″ which allows the configuration of thepartial enclosure 592 to engage thealternate hinge body 545 a′″ in a slightly different manner wherein the panel 336 does not abut against thehinge body 545 a′″ the same way that is shown inFIG. 18J . - The
hinge body 545 a′″ is shown in a further enlargement, shown inFIG. 17H , which is taken from the dashedcircle 17H ofFIG. 17G , which illustrates a portion of thehinge body 545 a′″ and thepartial enclosure 592 in which the hinge body is secured and also showing thegap 590 between afirst point 593 a on thelip 587 b of thesupport flange 586 b of thesupport bow 550 and asecond point 593 b at the lower corner of therigid panel 536. - In preferred embodiments of the present folding
tonneau cover assembly 530, thepreferred hinge body 545 a′″ will be made of a singlepolymeric material 547 a having a single durometer, as shown inFIGS. 17F, 17G, 17H, 18D, 18E and 18F and no adhesive material will be required to secure thehinge body 545 a′″ within thepartial enclosure 592 created in part by both thebottom surface 538 of the respectiverigid panel 536 and asupport bow 550 secured to thebottom surface 538 of therigid panel 536 on each side of thehinge 544 so as to secure therespective side portion intermediate portion partial enclosure 592. In other embodiments disclosed herein, various ways of incorporating adhesive materials into the foldingtonneau cover assembly 540 are used to secure therespective hinge body 545 a within the respectivepartial enclosure 592, but with this embodiment of thehinge body 545 a′″ it will be appreciated that thepartial enclosure 592 is sufficient to retain thehinge body 545 a′″ without having a need for adhesive material to secure thehinge body 545 a′″ within thepartial enclosure 592. Thehinge body 592 a′″ may also be made of multiple polymeric materials and be made of dual or multiple durometer material (not shown) and not require adhesive material for suitable securement in thepartial enclosure 592 and adhesive material can, of course, be used to secure the alternate hinge body within thepartial enclosure 592. - Referring now further to
FIGS. 17F, 17G and 17H , thepartial enclosure 592 on each side of thehinge body 545 a′″ is constructed and arranged to retain one of therespective side portions intermediate portions partial enclosure 592 without a need for any adhesive. It will be appreciated that the lack of a need for an adhesive is especially advantageous during the assembly process and also if a need arises to remove and replace the hinge body after manufacture. The key to retaining thehinge body 545 a′″ within thepartial enclosure 592 is the limited width of agap 590 that exists between afirst point 593 a on an inside surface of thelip 587 of thesupport flange 586 of the support bow orsupport member 550 that is secured to abottom surface 538 of theproximate panel 536 and asecond point 593 b at the bottom corner of the adjacentrigid panel 536. Thisgap 590 is constructed and arranged to be large enough to accommodate a portion of thehinge body 545 a′″ that resides between thecentral portion 546 a′″ and the respectiveintermediate portion 546 d′″, 546 e′″ to fit within thegap 590. As shown inFIG. 17H , the length ofgap 590, which is the same as the length of the dashedline 594, that extends from thefirst point 593 a on the inside surface of thelip 587 b to thesecond line 593 b at the lower corner of thebottom surface 538 of therigid panel 536. This dashedline 594, which has the same length as thegap 590, is longer than theline 576 that extends from theupper surface 595 of thehinge body 545 a′″, proximate thesecond point 593 b, to thelower surface 596 of thehinge body 545 a′″, proximate thefirst point 593 a.Lines line 576 and also parallel to dashedline 594. As can be seen,lines 577 a 577 b, and 577 c are each successively longer in length than theline 594 andline 576, because the width of theintermediate portion 546 d′″ and 546 e′″ on each side of thecentral portion 546 a′″ become progressively wider or larger as the lines grow progressively further away from thegap 590 and theupper surface 595 and thelower surface 596 diverge from one another as these respective surfaces become farther away from the gap in the immediate vicinity of theintermediate portions 546 d′″, 546 e′″, respectively. As the respectiveintermediate portion 546 d′″, 546 e′″ descends away from thecentral portion 546 a′″, thehinge thickness 545 d of the respectiveintermediate portion 546 d′″, 546 e′″ becomes enlarged, so much so that respective intermediate portion orshoulder 546 d′″, 546 e′″ is restricted from passing through thegap 590 under normal conditions that generally exist during the use of such a foldingtonneau cover assembly 530. This restriction is generally believed to be sufficient to prevent the disengagement of therespective shoulders 546 d′″, 546 e′″ andside portions 546 b′″, 546 c′″ from thepartial enclosure 592 under normal conditions generally experienced by truck owners. - The edges of the
gap 590 are generally unyielding because the preferredrigid panels 536 and the preferred support bows 550 are preferably made of aluminum which is generally unyielding when a polymeric material such as the polymeric material preferably used to make thehinge bodies 545 a of the present invention are drawing against the aluminum under great force. In most cases, the polymeric material will tear or deform before the aluminum material will bend significantly or break, but in any case, such levels of force are not generally expected under the anticipated conditions under which such tonneau cover assemblies are generally required to operate. As shown in the drawings, the thickness of the respective shoulder orintermediate portion 546 d′″, 546 e′″ of thehinge body 545 a′″ becomes greater as the thickness is measured inlines central portion 546 a′″ of thehinge body 545 a′″ increases in series: 577 a to 577 b to 577 c. Each of these lines are incrementally greater in length than line 575 that stretches from a point on theupper surface 595 of the hinge body proximate thesecond point 593 b on the lower corner of the most proximaterigid panel 536 to a point on thelower surface 596 proximate thefirst point 593 a on thelip 587 of the support flange respective 586. Each of thelines shoulder 546 d′″, 546 e′″ becomes wider or thicker as the shoulder becomes farther removed from thecentral portion 546 a′″ theshoulders 546 d′″, 546 e′″ and theside portions 546 b′″, 546 c′″ of thehinge body 545 a′″ are restricted from becoming disengaged from thepartial enclosure 592 by being drawn out of thepartial enclosure 592 through thegap 590. - In the embodiment schematically illustrated in
FIG. 18A , the configuration is similar to that illustrated inFIG. 5A ; the support bows 550 b and 550 c havehinge support flanges flange lips FIG. 5A . In the embodiment ofFIG. 18A , the arrangement preferably includes adhesive 570 a to secure and seal therespective side portions rigid panels - In the embodiment schematically illustrated in
FIG. 18B , the configuration is similar to that illustrated inFIG. 5A , except that analternate hinge 544′ is shown, having ahinge body 545 a′ that has a single hingebody polymer material 547 a (which preferably includes anelastomeric polymer material 547 b and more preferably includes a thermoplastic polymer as stated above) is used throughout thecentral portion 546 a′ and theside portions 546 b′ and 546 c′ of theflexible hinge body 545 a′. Preferably, bending of theflexible hinge body 545 a′ preferentially occurs in thecentral portion 546 a′ based on thehinge thickness 545 d of thecentral portion 546 a′ and theside portions 546 b′ and 546 c′ of theflexible hinge body 545 a′. - In the embodiment schematically illustrated in
FIG. 18C , the configuration is similar to that illustrated inFIG. 18B , but analternate hinge 544″ is shown, having ahinge body 545 a″ that hashinge body profile 545 c″ that is different, having a more uniformly flat profile in thecentral portion 546 a″ than in the embodiment illustrated inFIG. 18B . - In the embodiment schematically illustrated in
FIG. 18D , the configuration is similar to that illustrated inFIG. 18B , but analternate hinge 544′″ is shown, having ahinge body 545 a′″ but the adhesive 570 a is not used at theside portions 546 b′″ and 546 c′″ and instead thehinge thickness 545 d at theside portions 546 b′″ and 546 c′″ is such that eachside portion 546 b′″, 546 c′″ preferably contacts both the respectivehinge support flange respective bottom surface 538 of the respectiverigid panel 536 without intervening adhesive 570 a. - The portion of the
folding cover assembly 530 illustrated inFIG. 5A is schematically illustrated in further detail inFIG. 18E , which shows a portion of one of thepanels 536 broken away to show the underlying structure of thehinge 544′″, and which shows theflexible hinge body 545 a′″, and thecentral portion 546 a′″, and illustrates thepartial enclosure 592 in which a portion of the hinge body 545′″ is secured. - An enlarged view of the portion of the
flexible hinge 544′″ shown in the encircled area labeled 18F inFIG. 18E is illustrated inFIG. 18F . A portion of thehinge body 545 a′″ and thecentral portion 546 a′″, and thelip 587 are shown, and thehinge body 545 a′″ is partially enclosed in thepartial enclosure 592. Thelip 587 has apoint 593 a closest to thepanel 536. - The
partial enclosure 592 is illustrated inFIG. 18G in a further schematic perspective view similar toFIG. 18E but showing the structure of thepartial enclosure 592 with thehinge body 545 a shown only partially and in phantom, with therigid panels 536 and support bows 550 shown in cooperation with one another as shown inFIG. 18D . - A portion of the folding
tonneau cover assembly 530 is illustrated inFIG. 18H , which is an enlarged view providing a transverse vertical cross section of the portion of the folding tonneau cover assembly shown inFIG. 18A , but showing thehinge body 545 a in phantom. A portion of the foldingtonneau cover assembly 530 is illustrated inFIG. 18I in a further enlarged view similar to that shown inFIG. 18H , except that thehinge body 545 a is shown in cross section and therigid panels 536 and the support bows 550 are shown in phantom. - A further enlarged view of the portion of the folding
tonneau cover assembly 530 shown in the dashedcircle 18J ofFIG. 18I is illustrated inFIG. 18J . Portions of thepartial enclosure 592, hinge 544, hingebody 545 a,central portion 546 a,side portions intermediate portions body profile 545 c,hinge thickness 545 d, hinge adhesive 570 a, hinge bodyupper surface 595, and hinge bodylower surface 596 are shown. Portions of the support bows 550 andrigid panels 536 are shown in phantom. - Preferably, the
hinge thickness 545 d between the hingeupper surface 595 and the hingelower surface 596 is large enough in comparison to thegap 590 to provide a degree of securement of theflexible hinge body 545 a so that therespective side portion hinge support flange respective bottom surface rigid panel hinge thickness 545 d at the respectiveintermediate portion gap 590, thereby reducing the possibility of the respectiveintermediate portion gap 590 due to movements and stresses anticipated in use of the foldingtonneau cover apparatus 510. In embodiments which include the adhesive 570 a (such as the double-sidedadhesive tape 571 a, for example), the adhesive 570 a provides further securement of theflexible hinge body 545 a to the respectiverigid panels 536. - As described above, adhesive 570 a is preferably located between each
side portion cargo box 5; the adhesive 570 a can also aid in securement of theflexible hinge body 545 a to the respectiverigid panel 536. Alternatively, theside portions rigid panel 536, to provide a degree of protection against passage of debris or precipitation into thecargo box 5. Thefolding cover assembly 530 preferably includes support bows or channels 550 (550 a, 550 b, 550 c, 550 d, 550 e, 550 f, 550 g) secured to the underside 538 (538 a, 538 b, 538 c, 538 d) of at least some of therigid panels 536, near thefront edge 541 b and/or therear edge 541 c of the respectiverigid panels 536, and which extend between the driver's side and the passenger side of therigid panels 536. The support bows 550 are preferably secured to theunderside 538 of the respectiverigid panels 536 by adhesive 570 b. In preferred embodiments, the support bows 550 include thehinge support flanges 586. - The
extended flanges 586 are preferably separated a short distance from the respectiverigid panel 536, so that there is agap 590 between thehinge support flange 586 and the respectiverigid panel 536. Thehinge support flange 586 and the respectiverigid panel 536 form apartial enclosure 592 into which theside portions hinge support flanges 586 each preferably include a raisedlip flexible hinge body 545 a to the respectiverigid panel 536. The raised lip is preferably positioned to create a restrictedgap 590 between the raisedlip rigid panel 536, so that theside portion partial enclosure 592 through thegap 590, further securing theflexible hinge body 545 a to the respectiverigid panel 536. Theintermediate portion hinge thickness 545 d which does not permit theintermediate portion gap 590, further securing the flexible hinge body 445 a to the respectiverigid panel 536. In some embodiments, the geometry of thepartial enclosure 592,gap 590,side portion intermediate portion flexible hinge body 545 a to the respectiverigid panel 536 without the need for adhesive or other fastening mechanism. In other embodiments, adhesive 570 a is used to secure theflexible hinge body 545 a to the respectiverigid panel 536; in alternative embodiments, adhesive 570 a is located at an interface between theflexible hinge body 545 a and thehinge support flanges 586, adhesive 570 a is located at an interface between theflexible hinge body 545 a (at the hinge body upper surface 595) and the bottom surface orunderside 538 of the respectiverigid panel 536, or adhesive 570 a is located both at an interface between theflexible hinge body 545 a (at the hinge body lower surface 596) and thehinge support flanges 586 and at an interface between theflexible hinge body 545 a and the bottom surface orunderside 538 of the respectiverigid panel 536. In further embodiments, a mechanical interlock together with adhesive 570 a secures theflexible hinge body 545 a to the respectiverigid panel 536. In still further embodiments which include theflange lip 587, the mechanical interlock includes the geometry of the intermediate portion and the geometry of the lip. - As stated above, the
flexible hinge body 545 a preferably includespolymer material 547 a, which more preferably includes anelastomeric polymer material 547 b. In some embodiments, a single type ofelastomeric polymer material 547 b is used in thecentral portion 546 a,side portions intermediate portions flexible hinge body 545 a. In other embodiments, theflexible hinge body 545 a includes a plurality, i.e. more than one type ofpolymer material 547 a, which differ in elastic properties; for example, a more flexibleelastomeric polymer material 547 c may be preferably incorporated in thecentral portion 546 a and a stifferelastomeric polymer material 547 d may be preferably incorporated in theside portions intermediate portion elastomeric polymer material 547 c and the stifferelastomeric polymer material 547 d, and may provide a transition from the more flexibleelastomeric polymer material 547 c to the stifferelastomeric polymer material 547 d. In some embodiments, theflexible hinge body 545 a includes more than one type of polymer material to provide for more optimal properties in the various portions; for example, a more flexibleelastomeric polymer material 547 c may be utilized advantageously in thecentral portion 546 c to provide for bending of theflexible hinge body 545 a when folding or unfolding thefolding cover assembly 530, while a stifferelastomeric polymer material 547 d may be utilized advantageously in theside portion flexible hinge body 545 a to the respectiverigid panel 536. Preferably, in embodiments which incorporate more than one type ofpolymer material 547 a, theflexible hinge body 545 a is fabricated by co-extruding the more than one type ofpolymer material 547 a to form theflexible hinge body 545 a of materials which vary along thehinge body profile 545 c but which are generally the same along the hingelongitudinal axis 545 b of theflexible hinge body 545 a. - A portion of the folding
tonneau cover apparatus 510 that includes therear hinge 544 a, as indicated by the encircled area labeled 2D, 19A inFIG. 2C , is further illustrated in an enlarged partial phantom view inFIG. 19A , with the driver's-side side rail 220 a shown in phantom and thetruck 2 removed to show the underlying structure, and showing in phantom an alternate position of the same portion of the foldingtonneau cover apparatus 510 in which therear panel 536 a has been lifted up and rotated frontward somewhat in the direction of the arrow so that thehook 562 a is disengaged from thecatch 564 a. With further rotation of therear panel 536 a as illustrated inFIG. 19B , therear panel 536 a has been rotated completely forward onto themiddle panel 536 b, and thehook 562 a is disengaged from thecatch 564 a, so themiddle panel 536 b is free to be lifted up if desired. The other hooks 562 and catches 564 described herein function in a similar manner ashook 562 a and catch 564 a just described. - When it is desired to replace the folding cover assembly 230 onto the
cargo box 5 and cover thecargo box 5, the folding cover assembly 230 can be placed onto the side rails 520 and unfolded as schematically illustrated inFIG. 19C , beginning with (1) placing the bundledfolding cover assembly 530 on the side rails 520 with the hooks 562 at the front of thefront panel 536 c aligned with the respective catches 564 on the respective side rails 520; (2) lowering thefolding cover assembly 530 onto the side rails 520 until the latches 552 at the rear of thefront panel 536 c are engaged with theside rail lip 524 of the respective side rails 520 and thecontainment brackets folding cover assembly 530 can be left secured in this configuration, or if it is desired to unfold thefolding cover assembly 530 to cover thecargo box 5, thestrap brackets 543 b can be disengaged from thebracket slots 543 c, and (3) themiddle panel 536 b can be rotated rearward onto the side rails 520, with the hooks 562 at the front of themiddle panel 536 b engaging the respective catches 564, and (4) therear panel 536 a can be rotated rearward onto the side rails 520, with the hooks 562 at the front of therear panel 536 a engaging the respective catches 564 and the latches 552 at the rear of therear panel 536 a engaging with theside rail lip 524 of the respective side rails 520. -
FIGS. 20A-20E are schematic illustrations of the foldingtonneau cover apparatus 510 for various configurations ofcargo box 5 geometries as may be found onvarious trucks 2. Preferred embodiments of thefolding cover assembly 530 include therear panel 536 a, themiddle panel 536 b, thefront panel 536 c, and thespacer panel 536 d, as previously described. InFIGS. 20A-20E , theoverall length 533 of thefolding cover assembly 530 is shown for each example, and thelength 539 of each of thepanels 536 a-536 d is indicated as 539 a-539 d, respectively, and thewidth 540 of thepanels 536 a-536 d is indicated as 540 a-540 d, respectively, and theside angle 542 of thepanels 536 a-536 d is indicated as 542 a-542 d, respectively.Panels 536 a-536 c can havesimilar length 539 a-539 c, or the length of some or all ofpanels 536 a-536 c can differ.Panel 536 d can have asimilar length 539 d aspanels 536 a-536 c, but preferably thelength 539 d ofpanel 536 d is substantially smaller than thelengths 539 a-539 c ofpanels 536 a-536 c.Panels 536 a-536 d can havesimilar width 540, or the width of some or all ofpanels 536 a-536 d can differ.Panels 536 a-536 d can have thesame side angle 542, or theside angle 542 a-542 d of some or all ofpanels 536 a-536 d can differ. -
FIG. 20A shows thefolding cover assembly 530 as configured for a cargo box having angled sides; since this example foldingcover assembly 530 has angled sides, thewidth 540 is different at the front and rear of a panel. In this example, thewidth 540 of therear panel 536 a at the rear of therear panel 536 a is labeled 540 a′, to distinguish it from thewidth 540 a of therear panel 536 a at the front of therear panel 546 a. Thewidth 540 of thepanel 536 b at the rear of thepanel 536 b is similar to thewidth 540 a of thepanel 536 a at the front of thepanel 536 a, and so forth. -
FIG. 20B is a schematic illustration of thefolding cover assembly 530 as configured for a cargo box having parallel sides; in this example, thewidth 540 of each of the panels is similar.FIG. 20C is a schematic illustration of thefolding cover assembly 530 as configured for an elongated cargo box; in this example, theoverall length 533 is longer than in the example ofFIG. 20B .FIG. 20D is a schematic illustration of thefolding cover assembly 530 as configured for a shorter cargo box; in this example, theoverall length 533 is shorter than in the example ofFIG. 20B .FIG. 20E is a schematic illustration of thefolding cover assembly 530 as configured for a cargo box with arbitrary shape; in this example, the sides of thepanels 536 are angled, and the rear of therear panel 536 a is curved, extending acurved extension distance 539 e in the central portion with respect to the side portions of therear panel 536 a. Thefolding cover assembly 530 can be configured for a variety of other configurations oftruck box 5, with any of thepanels 536 a-536 d configured with straight or angled or curved shapes such as those illustrated in the examples ofFIGS. 20A-20E , in various combinations. - Further advantages to the structure described herein of the
flexible hinge 544 are illustrated inFIGS. 21A and 21B . Thehinge 544 as described herein is low profile, reducing the overall thickness, bulk, and weight of thefolding cover assembly 530. Theflexible hinge 544 can tolerate some deformation, so that ifadjacent panels 536 are not aligned perfectly, or are not perfectly flat, thehinge 544 can still function to allow thefolding cover assembly 530 to fold without binding. The configuration disclosed herein ofhinge 544 can accommodatepanels 536, some of which are preferably slightly bowed as described herein and illustrated inFIG. 16E .FIG. 21A is a schematic illustration of a portion of the foldingtonneau cover apparatus 510 showing a respectiveflexible hinge 544 interconnecting two respectiveadjacent panels 536, showing bent or bowed support bows 550 creating a bending or bowing of thepanels 536 attached thereto (see alsoFIGS. 16B-16E ), with the bending or bowing exaggerated for illustration, with thepanels 536 unfolded.FIG. 21B is a schematic illustration similar to that ofFIG. 21A , showing the two respectiveadjacent panels 536 folded up in the direction indicated by the arrow.FIGS. 21A-21B illustrate how theflexible hinge 544 can accommodate the folding up and unfolding of such bent or bowedpanels 536. -
FIG. 22 is a rear perspective view of an alternate embodiment of foldingtonneau cover apparatus 410 having afolding cover assembly 430 incorporating acab panel 436 e onto which the rear, middle, spacer, andfront panels tonneau cover apparatus 410 attached to apickup truck 2 which is shown in phantom. -
FIG. 23 is a bottom plan view of the foldingtonneau cover apparatus 410 ofFIG. 22 . Visible in this view are hinges 444, which are situated betweenadjacent panels 436 and adjoinadjacent panels 436. Eachpanel 436 has a top surface 437 and a bottom surface or underside 438;panel 436 a has atop surface 437 a and a bottom surface orunderside 438 a,panel 436 b has atop surface 437 b and a bottom surface orunderside 438 b,panel 436 c has atop surface 437 c and a bottom surface orunderside 438 c,panel 436 d has a top surface 437 d and a bottom surface orunderside 438 d, andpanel 436 e has atop surface 437 e and a bottom surface orunderside 438 e. For ease of discussion, hinges 444 are specifically referenced herein as 444 a-444 d, and non-specifically or collectively referenced as 444. Specifically, situated between therear panel 436 a and themiddle panel 436 b is hinge 444 a. Similarly, situated between themiddle panel 436 b and thespacer panel 436 d is hinge 444 b, situated between thespacer panel 436 d and thefront panel 436 c ishinge 444 c, and situated between thefront panel 436 c and thecab panel 436 e ishinge 444 d.Hinges 444 allow thefolding cover assembly 430 to be folded up and will be more fully described below.Optional hinge guards 463 are shown; hingeguards 463 provide additional support to thehinges 444 when thefolding cover assembly 430 is unfolded and in place covering thecargo box 5 of truck 2 (FIG. 22 ). Hinge guards 463 also provide protection against slicing through thehinges 444; further description of the hinge guards 463 is provided herein. Support bows 450 are attached to thepanels 436 to provide additional support and rigidity to thepanels 436, and also provide a structure for mounting of various other components as described in detail herein. For ease of discussion, support bows 450 are specifically referenced herein as 450 a-450 i, and non-specifically or collectively referenced as 450. Similar to supportbows bow end caps 565 shown inFIG. 3B ) are preferably secured to each end of the support bows 450. The foldingtonneau cover apparatus 410 is removably secured to thesupport frame assembly 418 by securing apparatus 451 a. Preferably, securing apparatus 451 a includes at least one locking member 451 b which is engageable and disengageable from thesupport frame assembly 418. Preferably, the locking member 451 b includes latches 452 which are located at the support bows as shown and secure thefolding cover assembly 430 to the side rails 420 a and 420 b. The latches are similar to latches 552, 652, 752 shown and described herein, and preferably include a latch slide with inclined bottom surface, an engaging portion, a spring, and a spring retainer, similar tocorresponding elements FIG. 33B and elsewhere herein. Release cords 454 are attached to the latches 452. For ease of discussion, release cords 454 are specifically referenced herein as 454 a, 454 d, and 454 f, and non-specifically or collectively referenced as 454. The release cords 454 pass through cord guides 455 which are attached to supportbows 450 as shown. For example, the cord guides 455 can be retainer cord guides 455 b, which are similar to retainer cord guides 555 b illustrated inFIG. 11B . The cord guides are non-specifically or collectively referenced herein as 455, but cord guides 455 c-455 d are specifically referenced herein to facilitate the detailed description herein.Standoffs 458 are shown, and are described in further detail herein. Sidebars or handles 459 are preferably attached topanels respective panel 436 to further support therespective panels 436.Perimeter seal 434 is located on the bottom 432 b of the folding cover assembly 330 and is arranged to seal against thesidewalls front wall 6 c and thetailgate 6 d of thecargo box 5; some portions ofperimeter seal 434 are behind side rails 420 a and 420 b and not visible inFIG. 23 . Theperimeter seal 434 is further described herein.Clamps 414 secure the side rails 420 a and 420 b to thesidewalls cargo box 5 in a similar manner asother clamps - The support bows or transverse frame members or
channels 450 provide additional support for thepanels 436. In this embodiment, the panels each have two support bows 450, one located near each of the front and rear ends of eachpanel 436, except for thespacer panel 436 d, which has only asingle support bow 450. In this embodiment, there are latches 452 mounted in pairs, one of each pair mounted near each end of each of the support bows 450 a, 450 f and 450 h as shown, similar to the latches 552, 652, 752 of other embodiments described herein. As further described herein, the latches 452 engage the side rails 420 a and 420 b to secure thefolding cover assembly 430, and can slide a short distance towards or away from the side rails 420 a and 420 b to engage or release thefolding cover assembly 430 or selectedpanels 436 or portions thereof from the side rails 420 a and 420 b as further described herein. In this embodiment, there are three latch release cords or release cords or cords 454, each of which are connected to opposing pairs of latches 452 which secure thepanels 436 to the side rails 420 a and 420 b. The release cords 454 pass through cord guides 455 which are mounted to the support bows 450; the release cords 454 can slide within the cord guides 455. The release cords 454 generally extend from the latches 452 along the support bows 450. The release cords 454 can be actuated to release each pair of latches 452 by a driver oroperator 8 when desired, to open thefolding cover assembly 430. Also seen onFIG. 23 areoptional hinge guards 463; theoptional hinge guards 463 are preferably attached to one of the support bows 450 adjacent to each of the respective hinges 444. In this example, the hinge guards 463 are shown attached to the support bows 450 b, 450 d, and 450 f. Optionally, hingeguards 463 can be attached to thesupport bow hinge 444 d in a similar manner. The hinge guards 463 provide support for thehinges 444, such as to support weight or pressure applied to thehinges 444, thepanels 436, or other portions of thefolding cover assembly 430. The hinge guards 463 can also provide some protection against cutting through ahinge 444 to enter thecargo box 5. - In the folding
tonneau cover apparatus 410, hooks 462 are attached to some of the support bows 450. Preferably, hooks 462 are located adjacent each end of each of the support bows 450 b, 450 d, and 450 i, and are aligned with respective catches 464 which are attached to the side rails 420 a and 420 b as illustrated. Similar to other embodiments further described herein, when thefolding cover assembly 430 is in place covering thecargo box 5, the hooks 462 are engaged with the catches 464 and help to secure thefolding cover assembly 430 to the side rails 420 a and 420 b. When apanel 430 is rotated upward, the hooks 462 disengage from the catches 464, allowing the panel to be rotated and stacked ontoother panels 430, as shown herein. Preferably, the hooks 462 slide into the support bows 450 and are secured in position; preferably, the hooks 462 are secured by an interference fit with the support bows 450, but other securement mechanisms can be utilized, such as screws or other fasteners or adhesives known in the art, or a combination of securement mechanisms. In various embodiments disclosed herein, hooks and catches such as hooks 462 and catches 464 are located along selected support bows 450, 550, 650, 750. In the foldingtonneau cover apparatus 410, hooks 462 a and 462 b are located near the driver's side end and passenger side end, respectively, ofsupport bow 450 b (near the front end of therear panel 436 a), hooks 462 c, 462 d onsupport bow 450 d (near the front end of themiddle panel 436 b); hooks 462 g and 462 h are located near the driver's side end and passenger side end, respectively, of support bow 450 i (near the front of thecab panel 436 e). Together, the various latches 452 and hooks 462 engage the catches 464 and the side rails 420 a and 420 b to secure thefolding cover assembly 430 to the side rails 420 a and 420 b and thereby to thecargo box 5 in order to cover thecargo box 5 when desired, but can be disengaged as described herein to open thefolding cover assembly 430 to enter thecargo box 5 when desired. Thecontainment brackets folding cover assembly 430 in position on the side rails 420 a. Similarly, thecontainment brackets 425 a′, 425 b′ are shown, which help to secure thefolding cover assembly 430 in position on the side rails 420 a, 420 b especially when thefolding cover assembly 430 is in a folded configurations such as those illustrated inFIGS. 30, 31A-31E . Note that in some embodiments, thecontainment brackets containment brackets 425 a′, 425 b′ are present. Preferably, thetonneau cover apparatus 410 includescontainment brackets -
FIG. 24 is a partial section view of the rear portion of the foldingtonneau cover apparatus 410 ofFIG. 22 as indicated onFIG. 23 and illustrating theedge guard 434 i at the rear portion of therear panel 436 a. Preferably, thefolding cover assembly 430 includes aperimeter seal 434, such as the perimeter seal 434 a (or other perimeter seals shown inFIGS. 15A-15E, 15G , for example) around substantially the entire perimeter, attached to the bottom surface 438 of each respective panel as described with regard to other embodiments herein. Preferably, thefolding cover assembly 430 also includes theedge guard 434 i (such as the edge guard 34 i shown inFIG. 15F ) at the rear portion of therear panel 436 a. This edge guard will minimize potential contusions or abrasions that may arise to anoperator 8, if theoperator 8 accidentally allows one or more of his or her fingers to rest of the top of the tailgate when securing the rear panel to the respective side rails. - Referring now to
FIGS. 25A-27 , hinges 444 include flexible sheet material orflexible material 447 which is attached to each of the adjacent panels 436 (specifically, respective adjacent panels of 436 a-436 d as described herein).Flexible sheet material 447 is moisture resistant to avoid leakage into thecargo box 5.Flexible sheet material 447 can include fabric, or a polymeric layer, and may have a reinforcing fiber which can be separate fibers, long (generally continuous) or short (generally discrete) fibers, fibrous yarns, or a web material, or woven material, single-axis or biaxial oriented fibers, or a braid or a felt of fibers, for example. For example,flexible material 447 can be a vinyl material, preferably a polyvinyl chloride or PVC covered fabric, a fiber-reinforced rubber or other flexible polymeric material, or a fabric having a water-resistant coating or impregnation. In additional examples, theflexible material 447 can be cloth-inserted EPDM rubber, cloth-inserted neoprene rubber, nylon cloth reinforced nitrile rubber, fiberglass-reinforced silicone rubber, polyester-reinforced neoprene sheet, nylon-reinforced neoprene sheet, and other materials available from multiple sources; information regarding example materials is available from www.rubbersheetroll.com and from www.mscdirect.com; note that not all materials listed on those web sites would be preferred for this application. A variety of materials could be used as flexible hinge material, such as neoprene, EPDM, flexible PVC, nitrile, natural rubber, flexible thermoplastics, silicone, latex, Hypalon rubber, butyl rubber, recycled rubber, Viton rubber, Santoprene rubber, Skirtboard rubber, SBR rubber, and so forth, that can be used in conjunction with a reinforcing fiber such as EPDM, Nylon, polyester, fiberglass, carbon fiber, aramid fibers, boron fibers, metal fibers, cellulose, wood-derived fibers, and so forth can be used for theflexible hinge material 447. The hinge orflexible hinge 444 is preferably made of a flexible material that can withstand deformation without failure due to cracking or breakage and that is selected from the group consisting of a laminated polymeric material, a fiber-reinforced polymeric material, an elastomeric material, a woven material and a laminated material that is includes a woven material and a moisture-resistant polymeric material. Preferably, ahinge material 447 is chosen that can be heat bonded to the thermaladhesive tape 471 a such as 3M 5933 from 3M, St. Paul, Minn. described herein. Other considerations in choosing an acceptableflexible hinge material 447 are durability over time and resistance to environmental factors such as precipitation, sunlight, temperature ranges, and physical stresses such as impacts and abrasions. Preferably, theflexible material 447 is polyester fiber reinforced polymeric material. More preferably,flexible material 447 is PVC-coated woven polyester material such as part number 90749 available from Lakeview Industries, Chaska, Minn. - Attachment of the
flexible sheet material 447 to thepanels 436 is preferably by an adhesive 470 a which may include a layer or coating of adhesive or a double-sidedadhesive tape 471 a for example. Alternatively, a contact adhesive, or a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a combination, can be used to attach theflexible sheet material 447 to thepanels adhesive tape 471 a can include anacrylic foam material 472 a, withadhesive layer 472 b arranged on one side of theacrylic foam material 472 a, andadhesive layer 472 c arranged on the other side of theacrylic foam material 472 a for example. Preferably, the adhesive 470 a includes a double-sidedadhesive tape 471 a such as 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), wherein the double-sidedadhesive tape 471 a is an acrylic foam tape having anacrylic foam material 472 a and anadhesive layer 472 b which includes heat-activated adhesive and anadhesive layer 472 c which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive,adhesive layer 472 c. Preferably, theadhesive layer 472 b (in this example, heat-activated adhesive) is aligned with theflexible sheet material 447 while the heat-activated adhesive is activated to adhere the double-sidedadhesive tape 471 a to theflexible sheet material 447; theflexible sheet material 447 together with the attached double-sidedadhesive tape 471 a is subsequently aligned with thepanel 436 and the release strip is removed. Preferably, after the adhesive layer 86 c is aligned with thepanel 436 theflexible sheet material 447 is attached to thepanel 436 by activating theadhesive layer 472 c (in this example, pressure-sensitive adhesive). Theadjacent panel 436 is similarly attached to theflexible sheet material 447 with double-sidedadhesive tape 472 a forming the structure ofhinge 444 as shown inFIG. 25B . Theflexible sheet material 447 allowshinges 444 to take a flat or open configuration as illustrated inFIGS. 25A and 25B , or to flex or bend as illustrated inFIGS. 25C, 26 and 27 , providing ahinge 444 that allows thefolding cover assembly 430 to fold as illustrated throughout the Figures and described herein, withpanels 436 folding up and rotating towards other panels as shown. Preferably, theflexible sheet material 447 is adhered to the respective bottom or underside 438 of the panels 436 (specifically, the underside 438 a-438 d of respective adjacent panels of 436 a-436 d as described herein) of thefolding cover assembly 430 as shown. In the preferred arrangements discussed herein, thehinges 444 are securely attached to therespective panels 436, are sealed to prevent water or debris from entering the cargo box through thefolding cover assembly 430 at thehinges 444, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which atypical cargo box 5 would be exposed. Preferably, thehinge 444 is low profile, so that the thin structure provides an effectively continuous seal along theperimeter seal 434 to prevent ingress of precipitation or debris or loss of contents from thecargo box 5, or lifting of the folding cover assembly by the wind under normal circumstances. All of the respective seals that are disclosed herein and can be used as aperimeter seal 434 are water resistant, preferably water proof such that water cannot flow through the seal material and is prevented from egress into thecargo box 5 through the respective seal material. In preferred embodiments, theperimeter seal 434 will be secured with an adhesive material to the underside of each of the respective panels proximate an outer portion of each of the respective panels and an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels, so that the passage of moisture through the juncture of any areas where such bonding occurs is minimized, if not entirely prevented. Furthermore, when theperimeter seal 434 is secured to each of the respective rigid panels proximate an outer portion of each of the respective panels and to an outer portion of each of the respective flexible hinges proximate the outer edges of each of the respective panels and compressed between the outer edges of each of the respective panels and each of the respective side rails 420 a, 420 b, the top of thetailgate 6 d and the top offront wall 6 c, wherein thecover assembly 430 is fully secured to thesupport frame assembly 418, theperimeter seal 434 will act to minimize the egress of moisture, wind and debris into thecargo box 5, preferably completely preventing moisture, wind and debris of any kind from entering thecargo box 5 when the cover assembly is fully secured to the support frame and the pickup truck. -
FIG. 25B also schematically illustrates support bows 450 which are preferably attached torespective panels 436 by an adhesive 470 b, which may include a layer or coating of adhesive or a double-sidedadhesive tape 471 b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows 450 to therespective panels 436. Double-sidedadhesive tape 471 b preferably includes anacrylic foam material 472 d, withadhesive layer 472 e arranged on one side of theacrylic foam material 472 d, andadhesive layer 472 f arranged on the other side of theacrylic foam material 472 d, for example. Preferably, the adhesive 470 b includes a double-sidedadhesive tape 471 b such as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sidedadhesive tape 471 b is an acrylic foam tape having anadhesive layer 472 e which includes pressure-sensitive adhesive and having anadhesive layer 472 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive,adhesive layer 472 f. Preferably, theadhesive layer 472 e (in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface 474 d of thesupport bow 450 to adhere the double-sidedadhesive tape 471 b to thesupport bow 450; thesupport bow 450 together with the attached double-sidedadhesive tape 471 b is subsequently aligned with thepanel 436 and the release strip is removed. Preferably, theadhesive layer 472 f is then aligned with thepanel 436, and thesupport bow 450 is attached to therespective panel 436 by activating theadhesive layer 472 f (in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and the acrylic foam material is also preferable but not always required. For example, in alternative configurations, a single layer of adhesive could be used, similar to the arrangement shown inFIG. 55A . Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles 459 are preferably also attached to the underside 438 of therespective panels 436, preferably in a similar manner as that just described for thesupport bow 450. Although adhesive 470 b can be applied at selected portions of the length of thesupport bow 450 or thesidebar 459, adhesive 470 b is preferably applied along substantially the entire length of thesupport bow 450 and thesidebar 459, to enhance stability and to minimize unwanted vibrations. Alternatively, thesidebars 459, support bows 450, or theflexible sheet material 447 ofhinges 444 can be attached to thepanels 436 with adhesives such as glue, or with fasteners, or spot welds. -
FIG. 26 is a schematic illustration showing the hinge ofFIG. 5B but with the hinge folded about 180 degrees. -
FIG. 27 is a schematic illustration showing a cross section similar to that ofFIG. 25C but showing a spacer panel and two adjacent hinges of the folding tonneau cover ofFIG. 22 illustrating both hinges in a partially folded configuration. -
FIG. 28 is a schematic illustration showing a preferred embodiment of general steps and configurations of the folding cover assembly ofFIG. 22 as it is folded up or unfolded. In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly 430 (configuration 1), thehinge 444 a flexes to allow therear panel 436 a to fold up, passing through 90 degrees (configuration 2) towards themiddle panel 436 b, and fold over onto themiddle panel 436 b (configuration 3). Thehinge 444 b flexes to allow themiddle panel 436 b (together with therear panel 436 a which is folded onto themiddle panel 436 b) to fold up, passing through 90 degrees (configuration 4) towards thespacer panel 436 d, passing through a point at which standoffs 458 contact the front panel (configuration 5). Thehinge 444 b flexes back towards 90 degrees ashinge 444 c flexes to allow thespacer panel 436 d to fold up, and continue to fold over (together with therear panel 436 a which is folded onto themiddle panel 436 b, and themiddle panel 436 b) towards thefront panel 436 c (configuration 6), until therear panel 436 a,middle panel 436 b, andspacer panel 436 d are folded onto thefront panel 436 c (configuration 7). Thehinge 444 d flexes to allow therear panel 436 a,middle panel 436 b,spacer panel 436 d, andfront panel 436 c to fold up into a generally vertical orientation onto thecab panel 444 d (configuration 8). Thehinge 444 d flexes further to allow therear panel 436 a,middle panel 436 b,spacer panel 436 d, andfront panel 436 c, folded up onto thecab panel 444 d, to be secured near or adjacent or touching the cab (configuration 9) with folded cover forward securingassembly 419, including various securing members 465 as are described below. Note thatFIG. 28 is a schematic overview of the general folding of thefolding cover assembly 430; the various configurations are further illustrated and described elsewhere herein in greater detail in relation to thefolding cover assembly 430 or otherfolding cover assemblies -
FIG. 29 is a side perspective view from the driver's side of the foldingtonneau cover apparatus 410 ofFIG. 22 , showing a configuration in which therear panel 436 a, themiddle panel 436 b, and thespacer panel 436 d are folded onto thefront panel 436 c and secured with storage straps 494 a. The various mechanisms and methods in releasinglatches 450, disengaging hooks 462 from catches 464, bending thehinges 444, rotating and folding up ofpanels 436 of thefolding cover assembly 430 to the configuration ofFIG. 29 are generally similar to those described herein in relation to foldingcover assemblies folding cover assembly 630 described herein. In this embodiment, the storage straps 494 a can attach to thepanel brackets 466 which are attached to thetop surface 437 e of thecab panel 436 e. Thefolding cover assembly 430 can be further folded up onto thecab panel 436 e as illustrated inFIG. 30 , andpanel brackets 466 also provide support to thepanels FIGS. 30-31E . This configuration allows entry into a substantial portion of thecargo box 5. If entry into a greater portion of thecargo box 5 is desired, then thefolding cover assembly 430 can be folded up onto thecab panel 436 e as shown inFIG. 30 ; as with other latches 52 described herein, the driver oroperator 8 can pullrelease cord 454 f to release thelatches support bow 450 h at the rear of thecab panel 436 e, disengaging them from the side rails 420 a, 420 b and thecontainment brackets 425 a′, 425 b′ in a manner similar to that already described herein with regard to other latches 552, 652, 752. In the configuration illustrated inFIG. 30 , therear panel 436 a, themiddle panel 436 b, thefront panel 436 c and the spacer panel or hingepanel 436 d are folded together and are turned upward on top of thecab panel 436 e, with therear panel 436 a, themiddle panel 436 b, and thefront panel 436 c, oriented in a generally vertically orientation while resting upon thecab panel 436 e. - The
folding cover assembly 430 can be secured in the generally vertical position with the with therear panel 436 a, themiddle panel 436 b, and thefront panel 436 c, oriented generally vertically, by securing member(s) 465 (such as cab strap 465 a, side strap 465 b, cab panel strap 465 c, securing magnet 465 d, or securing bracket 465 e) that are used to secure thefolding cover assembly 430 in this configuration, as illustrated inFIGS. 31A-31E . In some of the configurations illustrated inFIGS. 31A-31E , cab securement member(s) 467 (such ascab bracket 467 a or cab magnet 467 b) facilitate securement of thefolding cover assembly 430 with the securing member(s) 465 as shown.FIG. 31A , for example, illustrates cab straps 465 a which are secured tocab brackets 467 a which are preferably secured to thecab 4 by adhesive such asadhesives -
FIG. 31B illustrates a side strap 465 b which secures thefolding cover assembly 430 in position as shown. A side strap 465 b can be provided on both the driver's side and the passenger side, or on only one side. The side strap 465 b can form a single long loop which passes through the cab 4 (such as by temporarily opening the doors or the windows of the cab). Alternatively, the side strap 465 b can attach using a buckle to a separate strap which is secured inside thecab 4. -
FIG. 31C illustrates a cab panel strap 465 c which secures thefolding cover assembly 430 in position as shown. A cab panel strap 465 c can be provided on both the driver's side and the passenger side, or on only one side. The cab panel strap 465 c can attach to thecab panel 436 e; alternatively, the cab panel strap 465 c can attach using a buckle to a separate strap which is secured to thecab panel 436 e. -
FIG. 31D illustrates a securing magnet 465 d which secures thefolding cover assembly 430 in position as shown. A single securing magnet 465 d can be provided or a plurality of securing magnets 465 d can be provided. The securing magnet 465 d can magnetically attach to a cab magnet 467 b for securement to thecab 4. Alternatively, the securing magnet 465 d can magnetically attach to a portion of thecab 4. -
FIG. 31E illustrates a securing bracket 465 e which secures thefolding cover assembly 430 in position as shown. A securing bracket 465 e can be provided on both the driver's side and the passenger side, or on only one side. The securing bracket 465 e can retain themiddle panel 436 b and thefront panel 436 c and thecab panel 436 e in the illustrated configuration (with therear panel 436 a andspacer panel 436 d also held since they are attached to theother panels 436 by the hinges 444). Alternatively, the securing bracket 465 e can attach to the respective support bows 450 to secure the folding cover assembly in the illustrated configuration. In some embodiments, the securing bracket 465 e attaches to thepanel bracket 466. - Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated in
FIGS. 32-40H . A rear perspective view of a foldingtonneau cover apparatus 610 is illustrated inFIG. 32 , which includes asupport frame assembly 618, a folded cover forward securingassembly 619, and afolding cover assembly 630 incorporating acab panel 636 e onto whichrear panel 636 a,middle panel 636 b,spacer panel 636 d, andfront panel 636 c can fold, with the foldingtonneau cover apparatus 610 attached to apickup truck 2 which is shown in phantom, with acab 4, adrivers side 3 a, apassenger side 3 b, a front 3 c, and a rear 3 d. The foldingtonneau cover apparatus 610 is secured to thetruck 2 to cover acargo box 5 having adrivers side sidewall 6 a, apassenger side sidewall 6 b, afront wall 6 c (FIG. 40 ), and atailgate 6 d, which define atop opening 6 f (FIG. 40 ), acargo box length 7 a, and acargo box width 7 b. Preferably, thepanels 636 are secured toside rails FIG. 32 . Thefolding cover assembly 630 has a top 632 a and a bottom 632 b. - Preferably, the folded cover forward securing
assembly 619 secures the foldedfolding cover assembly 630 in an upright folded orientation in which the top orupper surface rear panel 636 a,middle panel 636 b,front panel 636 c, respectively, are in an upright or generally vertical orientation. The folded cover forward securingassembly 619 preferably includes twocab bracket assemblies 667 c, two cab braces 668 a, twostorage retainers 643 e, and twostorage straps 643 d. Alternatively, the folded cover forward securingassembly 619 can include other elements such as the securing members 465 disclosed herein, including the cab strap 465 a, the side strap 465 b, the cab panel strap 465 c, the securing magnet 465 d, the securing bracket 465 e thepanel bracket 466, the cab securement member 467, thecab bracket 467 a, the cab magnet 467 b (FIGS. 29-31E ) or combinations of the elements disclosed herein. - A top plan view of the
folding cover assembly 630 is illustrated inFIG. 32A , which shows thepanels 636, namely the rear, middle, front, spacer, andcab panels top surface length 639, namely 639 a, 639 b, 639 c, 639 d, 639 e, respectively; thefolding cover assembly 630 has alength 633, and agap 641 betweenadjacent panels 636. Thefolding cover assembly 630 preferably includesstorage retainers 643 e attached to thecab panel 636 e. - A bottom plan view of the folding
tonneau cover apparatus 610 is illustrated inFIG. 32B , which shows thefolding cover assembly 630, the bottom surfaces 638 a, 638 b, 638 c, 638 d, 638 e ofpanels side rails latches containment brackets folding cover assembly 630 with respect to the side rails 620 a, 620 b and thecargo box 5. Note that thespacer panel 636 d and correspondingbottom surface 638 d are obscured inFIG. 32B but are in the indicated location, behindsupport bow 650 e.Handles 659 are attached to the bottom surfaces 638 ofpanels adhesive tape 671 b or by other adhesive elements such as are described herein.Standoffs 658 are preferably attached tohandles 659 that are attached to therear panel 636 a as shown; thestandoffs 658 are preferably attached similar to the attachment ofstandoffs 558 to support bows 550 as illustrated inFIGS. 14A-14C . Thefolding cover assembly 630 preferably includesperimeter seal 634 located at the perimeter of thefolding cover assembly 630; various configurations of perimeter seal are envisioned, such as the perimeter seals 534, 534 a-534 k shown inFIGS. 15A-15H . Thecab panel 636 e is secured to the side rails 620 a, 620 b bycab panel retainers 679 and retainer bolt 678; two retainer bolts are illustrated as examples, including hex bolt 678 a and handle bolt 678 b (FIG. 32K ). - A side view of portions of the folding
tonneau cover apparatus 610 is illustrated inFIG. 32C , as viewed fromline 32C—32C ofFIG. 32A , and give further understanding of the relative positioning of the elements. Further detailed views of the foldingtonneau cover apparatus 610 are illustrated inFIGS. 32D-32F .FIG. 32D shows a portion of the foldingtonneau cover apparatus 610 as viewed fromline 32D-32D ofFIG. 32A , illustrating thespacer panel 636 d andadjacent hinges containment bracket 625 a which keepslatch 652 e in position when thelatch 652 e is engaged with the side rail lip 624 (FIG. 33B ) ofside rail 620 a and helps to maintain thefolding cover assembly 630 at the desired location to cover thecargo box 5. Similarly,FIG. 32E shows a portion of the foldingtonneau cover apparatus 610 as viewed fromline 32E-32E ofFIG. 32A , illustrating thefront hinge 644 d andadjacent panels alternative perimeter seal 634 j,storage retainer 643 e,cab panel retainer 679, and hex bolt 678 a, are illustrated. Atether 680, secured to supportbow 650 g (not visible onFIG. 32E ) byring 682, and link 681 are shown, which provide for an additional safety securement when the link is attached to theside rail 620 a at aperture 683 (FIG. 32J ) as illustrated onFIGS. 39C-E , for example. - As further illustrated in
FIGS. 32F and 32G , the folding tonneau cover apparatus preferably includes thestorage retainer 643 e, which is secured to the cab panel 626 e by aretainer fastener 643 k. Thestorage retainer 643 e preferably includes aretainer protrusion 643 h that engages a retainer slot 643 j in thecab panel 636 e to aid in maintaining proper position and orientation of thestorage retainer 643 e. Thestorage retainer 643 e also preferably includes aretainer hook 643 f to which astorage strap 643 d can be secured (FIG. 39E ) and aretainer nest 643 g which is configured and arranged to accommodate thefolding cover assembly 630 in a folded-up configuration as illustrated inFIG. 40A , for example. is an enlarged detailed front perspective view of a portion of the folding tonneau cover apparatus encircled by dashedline 32F-32F ofFIG. 32C , showing a storage retainer and a tether and link. - Portions of the folding tonneau cover apparatus of
FIG. 32 are illustrated inFIGS. 32H-J to show the structure and elements near passenger side of thespacer panel 636 d and thecab panel 636 e.Middle panel 636 b,front panel 636 c, and bottom surfaces of the middle panel, front panel, and cab panel, respectively, are shown, with thehook 662 f engaged with the catch 664 f, thelatch 652 f engaged with thecontainment bracket 525 b and theside rail 620 b,cab brace 668 a secured by cabbrace fastener assembly 668 d to thesupport bow 650 e and engaged withcab brace retainer 668 f. Therelease cord 654 c and handles 659 are also shown. Thetether 680 is secured to supportbow 650 g byring 682, and is also attached to link 681 which can be attached toside rail 620 b ataperture 683 for additional securement of thefolding cover assembly 630 to theside rail 620 b; similar elements are located at the drivers side of the foldingtonneau cover apparatus 610. Theretainer fastener 643 k can be seen engaged with thecab panel 636 e. Thecab panel retainer 679 is engaged with thesupport bow 650 h and is secured to theside rail 620 b by a retainer bolt 678, such as retainer hex bolt 678 a, although other fasteners such as retainer handle bolt 678 b (FIG. 32K ) can be utilized. - An alternative retainer handle bolt or lever clamp bolt 678 b is illustrated in
FIG. 32K ; also inFIG. 32K ; thetether 680 is not shown in this view. - Referring now to
FIGS. 33A and 33B , therelease cord 654 near the rear end of therear panel 636 a passes through cord guides 655, 655 c.FIG. 33B is an enlarged partial section view of the driver's side end portion of thesupport bow 650 a as indicated inFIG. 33A . The cord guides 655, 655 c are preferably molded and made of a strong polymer such as Nylon, which may be reinforced with fiberglass or other embedded material to strengthen the polymer. In alternate embodiments, the cord guides 655 can made of polymeric, metallic or ceramic materials using three-D printing methods or three-D etching methods or other additive or subtractive machining process. - As seen in
FIG. 33B , thelatch 652 a includeslatch slide 653 having an engagingportion 653 b which extends forward to engage thelip 624 of theside rail 620 a, so as to secure the panel 630 a to theside rail 620 a. Thelatch slide 653 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, thelatch slide 653 includes fiberglass-reinforced nylon. Thelatch slide 653 is biased by a biasing member orspring 656 towards theside rail 620 a so that the engagingportion 653 b engages theside rail 620 a to form a secured configuration in which therespective panel 636 is restricted from being lifted up from thecargo box 5; in this example, thespring 656 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias thelatch slide 653 towards theside rail 620 a so that the engagingportion 653 b engages theside rail 620 a so that the latch 652 is in the secured configuration. In this embodiment, thespring 656 is held between thelatch slide 653 and aspring retainer assembly 657. Thespring retainer assembly 657 is secured in the desired location in thesupport bow 650 a. The side rails 620 a and 620 b preferably include extruded metal, and have a siderail engagement portion 622 a, arranged to approximate a portion of thesidewall pickup truck 2. Theclamp 614 is shown in detail inFIG. 33B . Theclamps 614 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.Clamps 614 preferably have anouter member 616 a and aninner member 616 b which are tightened towards each other and held as an assembly on thesidewall 6 a by afastener assembly 616 d which preferably includes abolt 616 e, awasher 616 f, and anut 616 g. Preferably,inner member 616 b has aclamp engagement portion 616 c which, together with siderail engagement portion 622 a ofside rail 620 a, aids in securing theclamps 614 in place on theside rail 620 a. Preferably, theclamps 614 are arranged and tightened to secure theside rail 620 a to thesidewall 6 a, with asidewall gasket 622 c arranged between theside rail 620 a and thesidewall 6 a as illustrated. Abow end cap 665 is located at the end of thesupport bow 650 a. Arelease cord 654 and a cord guide 655 are shown, and will be described in further detail herein. In the present example, the siderail engagement portion 622 a is a generally vertically-oriented portion which configured to be located adjacent a similarly vertically-oriented portion of thesidewall FIG. 33B , a portion of thesidewall 6 a of acargo box 5 of a Chevrolet Silverado pickup truck is illustrated; however, other sidewalls of other cargo boxes of other pickup trucks and the like can be accommodated, by incorporating a siderail engagement portion 622 a along the length of the side rails 620 a and 620 b that are appropriately configured and oriented. In this example, thecargo box 5 of thepickup truck 2 includes asidewall cap 6 e, butother cargo boxes 5 lack a sidewall cap. Asidewall 6 a andsidewall cap 6 e are similarly illustrated in subsequent drawings herein. Preferably, the siderail engagement portion 622 a has a siderail engagement feature 622 b, such as ridges, knurling, surface patterns or textures, or other features which aid in securing theclamps 614. Preferably, asidewall gasket 622 c preferably made of polymeric material is located between the siderail engagement portion 622 a and thesidewall 6 a; thesidewall gasket 622 c can provide protection against damage to thesidewall 6 a by abrasion against theside rail 620 a. Other flexible material can also be used. Thesidewall gasket 622 c can provide leak resistance to prevent water, dust, or other debris from passing into thecargo box 5 along the siderail engagement portion 622 a. Theside rail 620 a has a flange orside rail lip 624 along the length of theside rail 620 a. Theside rail lip 624 provides support for thefolding cover assembly 630. In addition, theside rail lip 624 provides a feature for engagement of the engagingportion 653 b of the latches 652. The driver's side portion of thesupport bow 650 a is shown inFIG. 33B ; the other end of thesupport bow 650 a (toward the passenger side) has a mirror-image configuration, with a latch 652engaging side rail 620 b, andside rail 620 b being attached tosidewall 6 b in a similar manner. - As illustrated in
FIGS. 34A and 34B , when it is desired to release the latches 652 at the rear end of therear panel 636 a, therelease cord 654 a can be pulled, which will retract each of the latches 652 against the force of the respective biasing member orspring 656. Typically, therelease cord 654 a will be pulled as illustrated inFIG. 34A , by anoperator 8 who has walked to the rear of thecargo box 5 and has opened thetailgate 6 d and reaches in to access and pull therelease cord 654 a. When therelease cord 654 a is pulled, the engagingportion 653 b of the latch 652 is retracted away from thelip 624 of theside rail 620 a as shown inFIG. 34B , releasing the latch 652 from theside rail 620 a and allowing the rear portion of therear panel 636 a to be lifted up from theside rail 620 a. The cord guides 655 adjacent to the latches 652 help to maintain alignment of the ends of therelease cord 654 a so that the latches 652 are retracted in alignment with thesupport bow 650 a, to avoid excessive friction, wear and potential binding. The driver's side portion of thesupport bow 650 a is shown inFIG. 34B ; the other end of thesupport bow 650 a (toward the passenger side) has a mirror-image configuration, and when therelease cord 654 a is pulled, the latches 652 at both ends of thesupport bow 650 a are retracted, so that the rear end of therear panel 636 a can be lifted up from bothside rails - Referring now also to
FIGS. 35A-35D , which illustrate a portion of thefolding cover assembly 630 in schematic cross section views as indicated by theline 35A-35A inFIG. 32A , each of the hinges 644 (644 a, 644 b, 644 c, and 644 d) preferably includes theflexible hinge body 645 a which is elongated and extends between the driver'sside 3 a and thepassenger side 3 b of thecargo box 5 when thefolding cover assembly 630 is unfolded to cover thecargo box 5. Theflexible hinge body 645 a is similar to theflexible hinge body 545 a ofFIG. 17C , with similar elements and configuration, with a hinge longitudinal axis 645 b which is oriented along the length of thehinge body 645 a, and ahinge body profile 645 c, which is the shape of a transverse vertical cross section taken perpendicular to the hinge longitudinal axis 645 b (not shown separately; refer to corresponding elements forflexible hinge body 545 a inFIG. 17C , including the hingelongitudinal axis 545 b which is oriented along the length of thehinge body 545 a, and thehinge body profile 545 c, which is the shape of a transverse vertical cross section taken perpendicular to the hingelongitudinal axis 545 b). Thehinge body profile 645 c is preferably uniform along the hinge longitudinal axis 645 b of thehinge body 645 a. In embodiments having more than oneflexible hinge 644, each of theflexible hinges 644 can have a similarhinge body profile 645 c. Alternatively, thehinge body profile 645 c of theflexible hinge bodies 645 a can differ from the profile of at least one other of theflexible hinge bodies 645 a. - The
hinge 644 preferably includes ahinge body 645 a, which is similar to thehinge body 545 a described herein; several hinge body embodiments are shown and described in detail elsewhere herein, includinghinge body 545 a,hinge body 545 a′, hingebody 545 a″, and hingebody 545 a′″ (FIGS. 17C-18F ). - In preferred embodiments illustrated in
FIGS. 35A-35C ,flexible hinge body 645 a includescentral portion 646 a,side portion 646 b, andside portion 646 c. Adhesive 670 a is preferably located between eachside portion rigid panel 636 as illustrated inFIG. 35A to protect against passage of debris or precipitation into thecargo box 5; the adhesive 670 a can also aid in securement of theflexible hinge 644 to the respectiverigid panel 636. The adhesive 670 a can include known adhesives and sealant materials which can be used to protect against passage of debris or precipitation between therigid panel 636 and the respectiveflexible hinge 644 or to secure theflexible hinge 644 to the respectiverigid panel 636. In some preferred embodiments, the adhesive 670 a includes a double-sidedadhesive tape 671 a, which preferably includes anacrylic foam material 672 a, withadhesive layer 672 b arranged on one side of theacrylic foam material 672 a, andadhesive layer 672 c arranged on the other side of theacrylic foam material 672 a, for example. For example, the double-sidedadhesive tape 671 a can be 3M 5933 from 3M, St. Paul, Minn. (“thermal adhesive tape”), theadhesive layer 672 b includes heat-activated adhesive and anadhesive layer 672 c includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive layer 672 c. Preferably, theadhesive layer 672 b (in this example, heat-activated adhesive) is aligned with theflexible hinge body 645 a while the heat-activated adhesive is activated to adhere the double-sidedadhesive tape 671 a to theflexible hinge body 645 a; theflexible hinge body 645 a together with the attached double-sidedadhesive tape 671 a is subsequently aligned with therigid panel 636 and the release strip is removed. Preferably, after theadhesive layer 672 c is aligned with thepanel 636, theflexible hinge body 645 a is attached to therigid panel 636 by activating theadhesive layer 672 c (in this example, pressure-sensitive adhesive). The adjacentrigid panel 636 is similarly attached to theflexible hinge body 645 a with double-sidedadhesive tape 671 a forming the structure ofhinge 644 illustrated inFIG. 35B . Theflexible hinge body 645 a allows thehinge 644 to take a flat or open configuration as illustrated inFIGS. 35A and 35B , or to flex or bend as illustrated inFIG. 35C , and other figures herein, providing aflexible hinge 644 that allows thefolding cover assembly 630 to fold as illustrated throughout the Figures and described herein, withrigid panels 636 folding up and rotating towards otherrigid panels 636 as shown. Preferably, theflexible hinge body 645 a is adhered to the respective bottom orunderside 638 of the rigid panels 636 (specifically, theunderside 638 a-638 e off respective adjacent panels of 636 a-636 ed as described herein) of thefolding cover assembly 530 as shown. In the preferred arrangements discussed herein, the hinges 44 are securely attached to the respectiverigid panels 636 and are sealed to prevent water or debris from entering the cargo box through thefolding cover assembly 630 at thehinges 644, and are generally impervious to environmental factors such as precipitation, wind, and temperatures to which atypical cargo box 5 would be exposed. - The support bows 650 are also schematically illustrated in
FIGS. 35A-35C . The support bows 650 are similar to support bows 550 described herein (FIGS. 16A-16K ) which preferably include a bowmain portion 584 including a generally C-shaped channels with a bowupper portion 585 configured for attachment to thebottom surface 538 of therespective panel 536 and oriented with achannel opening 566 c at the bottom. The support bows 650 which are located at theflexible hinges 644 preferably include a hinge support flange 686 similar to hingesupport flange flexible hinges 644 preferably also include a flange lip similar toflange lip - As stated above, the support bows 650 are secured to the
respective panel 636. The support bows 650 are preferably located at thebottom surface 638 of therespective panel 636, and near the front edge 641 b or rear edge 641 c of therespective panel 636. The support bows 650 are preferably secured to thebottom surface 638 of therespective panel 636 by an adhesive 670 b, which may include a layer or coating of adhesive or a double-sidedadhesive tape 671 b, for example. Alternatively, a thermal or hot-melt or chemically activated adhesive, or a mechanical attachment, or a weld, or a combination, can be used to attach the support bows 650, to therespective panels 636. The double-sidedadhesive tape 671 b preferably includes anacrylic foam material 672 d withadhesive layer 672 e arranged on one side of theacrylic foam material 672 d andadhesive layer 672 f arranged on the other side of theacrylic foam material 672 d, for example. Preferably, the adhesive 670 b includes a double-sidedadhesive tape 671 b such as 3M CV62F from 3M, St. Paul, Minn. (“pressure adhesive tape”), wherein the double-sidedadhesive tape 671 b is an acrylic foam tape having anadhesive layer 672 e which includes pressure-sensitive adhesive and having anadhesive layer 672 f which includes pressure-sensitive adhesive which may be protected by a release strip (not shown) until it is desired to activate the pressure-sensitive adhesive,adhesive layer 672 f. Preferably, theadhesive layer 672 e (in this example, pressure-sensitive adhesive) is aligned with and adhered to the upper surface 666 d of thesupport bow 650 to adhere the double-sidedadhesive tape 671 b to thesupport bow 650; thesupport bow 650 together with the attached double-sidedadhesive tape 671 b is subsequently aligned with thepanel 636 and the release strip is removed. Preferably, theadhesive layer 672 f is then aligned with thepanel 636 and thesupport bow 650 is attached to therespective panel 636 by activating theadhesive layer 672 f (in this example, pressure-sensitive adhesive). While the arrangement just described is a preferred configuration, any of the adhesive layers just described can include heat-activated adhesive or pressure-sensitive adhesive, and theacrylic foam material FIG. 35A . Other pressure-activated acrylic adhesive foam tape can be used, such as Lamatek 5357 from Lamatek, Inc., West Deptford, N.J. The sidebars or handles 659 are preferably also attached to the bottom surface orunderside 638 of therespective panels 636, preferably in a similar manner as that just described for thesupport bow 650. Although adhesive 670 b can be applied at selected portions of the length of thesupport bow 650 or thesidebar 659, adhesive 670 b is preferably applied along substantially the entire length of thesupport bow 650 and thesidebar 659, to enhance stability and to minimize unwanted vibrations. Alternatively, thesidebars 659 and support bows 650 can be attached to thepanels 636 with adhesives such as glue, or with fasteners, or spot welds. - In some apparatus and methods embodiments, the
folding cover assembly 630 folds in stages or steps; a preferred embodiment is schematically illustrated inFIG. 35D . In this embodiment, starting from the unfolded or closed configuration of the folding cover assembly 630 (configuration 1), thehinge 544 a flexes to allow therear panel 636 a to fold up, passing through 90 degrees (configuration 2) towards themiddle panel 636 b, and fold over onto themiddle panel 636 b (configuration 3). Thehinge 644 b flexes to allow themiddle panel 636 b (together with therear panel 636 a which is folded onto themiddle panel 636 b) to fold up, passing through 90 degrees (configuration 4) towards thespacer panel 636 d, passing through a point at which standoffs 658 contact the front panel (configuration 5). Thehinge 644 b flexes back towards 90 degrees as thehinge 644 c flexes to allow thespacer panel 636 d to fold up, and continue to fold over (together with therear panel 636 a which is folded onto themiddle panel 636 b, and themiddle panel 636 b) towards thefront panel 636 c (configuration 6), until thefolding cover assembly 30 is folded up onto thefront panel 636 c (configuration 7). Thehinge 644 d flexes to allow thefront panel 636 c (together with therear panel 636 a,middle panel 636 b, andspacer panel 636 d) to a generally vertical orientation onto thecab panel 636 e (configuration 8). Thecab brace 668 a secures to thecab bracket assembly 667 c to secure thefolding cover assembly 630 adjacent to thecab 4. Note thatFIG. 35D is a schematic overview of the general folding of thefolding cover assembly 630; the various configurations are further illustrated and described elsewhere herein in greater detail. - Once the latches 652 at both ends of the
support bow 650 a are retracted as shown inFIGS. 34A and 34B and described above, the rear end of therear panel 636 a can be lifted up from bothside rails hinge 644 a as illustrated inFIGS. 36A and 36B . As shown inFIG. 36B , the engagingportion 653 b of thelatch slide 653 oflatch 652 c is engaged with theside rail 620 a to restrict themiddle panel 636 b from being lifted up from thecargo box 5. - The
rear panel 636 a is rotated further, onto themiddle panel 636 b as illustrated inFIGS. 37A and 37B . At this point, the engagingportion 653 b oflatch slide 653 of thelatch 652 c is engaged with theside rail 620 a to restrict themiddle panel 636 b from being lifted up from thecargo box 5. When it is desired to release the latches 652 at the rear end of themiddle panel 636 b, therelease cord 654 b can be pulled, which will retract each of thelatches spring 656, as shown inFIG. 37C , releasing the latches 652 from the side rails 620 a and 620 b and allowing the rear portion of therear panel 636 a to be lifted up from the side rails 620 a and 620 b. The driver's side portion of thesupport bow 650 c is shown inFIGS. 37B-37C ; the other end of thesupport bow 650 c (toward the passenger side) has a mirror-image configuration, and when therelease cord 654 b is pulled, the latches 652 at both ends of thesupport bow 650 c are retracted, so that the rear end of themiddle panel 636 b, together with therear panel 636 a, can be lifted up from bothside rails - Once the latches 652 at both ends of the
support bow 650 b are retracted as shown inFIG. 37C and described above, the rear end of themiddle panel 636 b can be lifted up from bothside rails hinge 644 b as illustrated inFIGS. 38A and 38B .FIG. 38A shows the configuration in which therear panel 636 a is folded over onto themiddle panel 636 b and wherein both therear panel 636 a and themiddle panel 636 b have been lifted up and pivoted forward generally about 90 degrees with respect to thefront panel 636 c that is resting on the side rails 620 a, 620 b and is generally in a horizontal plane with respect to the pickup truck which is shown in part in phantom. Thehook 662 d is disengaged from thecatch 664 d as themiddle panel 636 b is lifted up from thecargo box 5, as shown inFIG. 38B . - With continued lifting and rotating of the
middle panel 636 b frontwards, themiddle panel 636 b together with therear panel 636 a rotates frontwards towards thefront panel 636 c. Preferably, thefolding cover assembly 630 includes 4standoffs 658. Thestandoffs 658 are preferably attached to thehandles 659 near the front and back of thepanel 636 a as shown inFIG. 37A and elsewhere herein; alternatively, thestandoffs 658 can be attached to thebottom surface 638 a of therear panel 636 a or attached to other structures such as support bows 650 a, 650 b. Thestandoffs 658 are preferably located so that two are proximate the front edge 641 b of therear panel 636 a, and two are proximate the rear edge 641 c of therear panel 636 a. Through the folding and rotating of themiddle panel 636 b together with therear panel 636 a as just described, thestandoffs 658 proximate the rear edge 641 c of therear panel 636 a contact thetop surface 637 c of thefront panel 636 c and help to maintain a spaced relationship between therear panel 636 a and thefront panel 636 c. With continued rotating of themiddle panel 636 b (together with thefront panel 636 a) thehinge 644 c bends and thespacer panel 636 d lifts off the side rails 620 a and 620 b, and themiddle panel 636 b, therear panel 636 a, and thespacer panel 636 d rotate progressively farther frontwards towards thefront panel 636 c until thestandoffs 658 all contact thefront panel 636 c (FIG. 39A ). During this folding of thefolding cover assembly 630, thehinges middle panel 636 b, therear panel 636 a, and thespacer panel 636 d rotate towards thefront panel 636 c. The configurations as thefolding cover assembly 630 is folded up in this manner are similar to those illustrated for folding up of thefolding cover assembly 530 inFIGS. 8A-9A . When thefolding cover assembly 630 is folded onto thefront panel 636 c, therear panel 636 a,middle panel 636 b,front panel 636 c, andcab panel 636 e are approximately parallel to each other, and preferably oriented about horizontally, provided thecargo box 5 andside rails spacer panel 636 d is preferably oriented approximately vertically, although it can be somewhat off vertical as illustrated inFIGS. 5E and 5F for alternatefolding cover assemblies 530′ and 530″. - At this point, as illustrated in
FIGS. 39A-39E, and 10A , thefolding cover assembly 630 is folded up, but is still “flat” on thecargo box 5 and still attached to the side rails 620 a and 620 b, with thelatches support bow 650 f) engaged with theside rail lip 624 of the side rails 620 a and 620 b, respectively, as illustrated inFIGS. 39A-39B . In the view ofFIG. 39B , a portion of the driver's side of the partially foldedfolding cover assembly 630 is illustrated, showing the engagingportion 653 of thelatch 652 e near the driver's-side end portion of thesupport bow 650 f engaged with thelip 624 of the driver'sside side rail 620 a and thecontainment bracket 625 a. Thelink 681 attached to tether 680 is shown detached from theside rail 620 a for illustration. - When it is desired to release the
latches front panel 636 c, therelease cord 654 c can be pulled, which will retract each of thelatches spring 656, as shown inFIG. 39C , releasing the latches 652 from the side rails 620 a and 620 b and allowing the rear portion of thefront panel 636 a to be lifted up from the side rails 620 a and 620 b. Thelink 681 attached to tether 680 is shown attached from theside rail 620 a. -
FIG. 39D shows a portion of the foldingtonneau cover apparatus 610 in the configuration illustrated inFIGS. 39A-39B , but seen from theline 39D,E-39D,E ofFIG. 39A illustrating the driver's side of the partially folded tonneau cover assembly. In this view, thestorage strap 643 d is seen, not secured to thestorage retainer 643 e. Astandoff 658 is also shown. Thestorage strap 643 d can be pulled down and secured to thestorage retainer 643 e as shown inFIG. 39D (by engaging thestorage strap 643 d with theretainer hook 643 f shown inFIG. 32G ). - With the
rear panel 636 a,middle panel 636 b,front panel 636 c andspacer panel 636 d secured to thecab panel 636 e, theoperator 8 can lift up therear panel 636 a,middle panel 636 b,front panel 636 c andspacer panel 636 d onto thecab panel 636 e, disengage the two cab braces 668 a from thecab brace retainers 668 f (FIG. 40C ), pivot the cab braces 668 a forward and secure the cab braces 668 a to thecab bracket assemblies 667 c to secure the folded-upfolding cover assembly 630 in a generally vertical orientation adjacent thecab 4 as illustrated inFIG. 40 . In this configuration, theoperator 8 can attach or detach the cab braces 668 a from thecab bracket assemblies 667 c, or actuate the retainer hex bolts 678 a or retainer handle bolts 678 b to disengage thefolding cover assembly 630 from the side rails 620 a, 620 b to remove thefolding cover assembly 630 from thesupport frame assembly 618 or attach thefolding cover assembly 630 to thesupport frame assembly 618 as desired. - The
folding cover assembly 630 is further illustrated in a folded-up vertical configuration inFIG. 40A , which shows therear panel 636 a,middle panel 636 b,front panel 636 c andspacer panel 636 d rotated onto thecab panel 636 e and engaged with theretainer nest 643 g of each of thestorage retainers 643 e, and thestandoffs 658 maintaining the separation of therear panel 636 a and thefront panel 636 c. Thetether 680 is secured by attaching thelink 681 to theaperture 683 in theside rail 620 a. InFIG. 40A , eachcab brace 668 a is secured to thesupport bow 650 e by acab brace retainer 668 f. A detailed view of a portion of thefolding cover assembly 630 is illustrated inFIG. 40C , which shows one of the cab braces 668 a secured to thesupport bow 650 e which is secured to thebottom surface 638 d of thespacer panel 636 d. Thecab brace 668 a is secured to thesupport bow 650 e by the cabbrace fastener assembly 668 d and by thecab brace retainer 668 f. The cab bracesecond end portion 668 c is also shown. -
FIG. 40D is a similar view asFIG. 40C , but shows the cab brace disengaged from thecab brace retainer 668 f. The cab brace first end portion 668 g and cab brace first end portion top surface 668 i, the cabbrace body portion 668 b and cab brace body portion top surface 668 h, and the cab bracesecond end portion 668 c and cab brace second endportion top surface 668 j are also shown. In most cases, thesupport bow 650 e of thefolding cover assembly 630, when in a generally vertical configuration such as that illustrated inFIG. 40B , will be at a similar height or somewhat higher than thecab 4. Depending on the relative height of thesupport bow 650 e and thecab 4, the cab bracesecond end portion 668 c is preferably bent upward at acab brace angle 668 e that is preferably between about 1 degree to about 16 degrees, so that the cab bracesecond portion 668 c engages theanchor post 667 f (FIG. 40G ) perpendicularly. In one example, thecab brace angle 668 e′ is about 5 degrees; in another example, thecab brace angle 668 e″ is about 15 degrees. The cab bracesecond end portion 668 c is preferably adapted to secure to thecab bracket assembly 667 c. In preferred embodiments, thesecond end portion 668 c includes a material which can be attracted by a magnet, such as a steel material, and thecab bracket assembly 667 c includes a cab bracket magnet 667 to aid in retaining thecab brace 668 a securely to thecab bracket assembly 667 c. A preferred material for thecab brace 668 a is ASTM A36 pickled and oiled hot-rolled steel, preferably about 0.125 inch thick. - If the
support bow 650 e is much higher than thecab 4, so that thecab brace angle 668 e would be greater than about 16 degrees, thecab brace 668 a is preferably secured to an auxiliary support bow 650 j which is secured to thebottom surface 638 b of themiddle panel 636 b. The auxiliary support bow 650 j is preferably oriented so that the cab brace is secured below the auxiliary support bow 650 j as illustrated. The auxiliary support bow 650 j is preferably secured to thebottom surface 638 b of themiddle panel 636 b by double-sidedadhesive tape 671 b, although other adhesive 670 b such as described herein can be utilized. Preferably, the auxiliary support bow 650 j is secured to themiddle panel 636 b at a desired location so that the cab brace angle 668 is less than about 16 degrees. In this configuration, the cab bracesecond end portion 668 c is co-planar with the cabbrace body portion 668 b, and thecab brace angle 668 e is zero. - The
cab bracket assembly 667 c is further illustrated inFIGS. 40F-40H . Thecab bracket assembly 667 c preferably includes acab bracket body 667 d, which includes a cab bracket protrusion or 667 f. Thecab bracket assembly 667 c preferably includes acab bracket magnet 667 e that is secured to thecab bracket body 667 d by acab magnet retainer 667 h. Thecab bracket assembly 667 c is preferably secured to thecab 4 by cab bracket adhesive 667 j. The cab bracket adhesive 667 j is preferably an adhesive foam tape such as Tesa 7078 acrylic foam tape. Other adhesive such as double-sidedadhesive tape 671 b or other adhesives such as those described herein can be utilized. - Another preferred embodiment of the folding tonneau cover apparatus of the present invention is illustrated in
FIGS. 41-48 . A rear perspective view of the folding tonneau cover apparatus or hingedtonneau cover apparatus 710 is illustrated inFIG. 41 , which includes asupport frame assembly 718, and a folding cover assembly or hingedcover assembly 730 incorporating acab panel 736 e from which arear panel 736 a can fold, illustrated with the folding or hingedtonneau cover apparatus 710 attached to apickup truck 2 which is shown in phantom, with acab 4, adrivers side 3 a, apassenger side 3 b, a front 3 c, and a rear 3 d. The foldingtonneau cover apparatus 710 is secured to thetruck 2 to cover acargo box 5 having adrivers side sidewall 6 a, apassenger side sidewall 6 b, afront wall 6 c (FIG. 48 ), and atailgate 6 d, which define atop opening 6 f (FIG. 48 ), acargo box length 7 a, and acargo box width 7 b. Preferably, the panels 736 are secured toside rails FIG. 41 . Thefolding cover assembly 730 has a top 732 a and a bottom 732 b. - A top plan view of the
folding cover assembly 730 is illustrated inFIG. 42A , which shows thepanels 636, namely therear panel 736 a and thecab panel 736 e, each having atop surface folding cover assembly 730 has alength 733 and a top 732 a. Thefolding cover assembly 730 preferably includes storage retainers 743 e attached to thecab panel 736 e. - A bottom plan view of the folding
tonneau cover apparatus 710 is illustrated inFIG. 42B , which shows thefolding cover assembly 730, the bottom surfaces 738 a, 738 e ofrear panel 736 a andcab panel 736 e, respectively, and support bows 750, includingsupport bow 750 a (rear ofrear panel 736 a),support bow 750 b (front ofrear panel 736 a),support bow 750 h (cab panel 736 e), and intermediate support bow(s) 750 spaced along therear panel 736 a betweensupport bow 750 a andsupport bow 750 b. Also shown arelatches side rails Handles 759 are attached to the bottom surface 738 ofrear panel 736 a, preferably by adhesive 770 b (similar to adhesive 670 b illustrated onFIG. 35A ) or other adhesive elements such as are described herein. Preferably, adhesive 770 b is double-sided adhesive tape 771 b (FIG. 35C ).Handles 759 are preferably attached to thebottom surface 738 a of therear panel 736 a as shown; the standoffs 758 are preferably attached in a similar manner as the attachment ofstandoffs 558 to support bows 550 as illustrated inFIGS. 14A-14C . The foldingtonneau cover apparatus 710 also preferably includes a driversside support beam 773 a and a passengerside support beam 773 b which are secured to thehandles 759 to provide additional structural support to therear panel 736 a. The foldingtonneau cover apparatus 710 also preferably includes two lift supports or gas struts 774, with agas strut 774 secured by a gas strut supportbeam fastener assembly 775 a to the driversside support beam 773 a and by a gas strut siderail fastener assembly 775 b to the driversside side rail 720 a, and agas strut 774 secured by a gas strut supportbeam fastener assembly 775 a to the driversside support beam 773 a and by a gas strut siderail fastener assembly 775 b to the drivers side side rail 720. Suitable gas struts are available, for example from SUSPA® Inc., 3970 Roger B. Chaffee Memorial Dr., Grand Rapids, Mich. 49548. Alternate gas struts are available from various sources. Thefolding cover assembly 730 preferably includes snap clips 776 for securing the gas struts 774 to the support beams 773 a, 773 b when thefolding cover assembly 730 is not attached to thetruck 2. Thefolding cover assembly 730 preferably includesperimeter seal 734 located at the perimeter of thefolding cover assembly 730; various configurations of perimeter seal are envisioned, such as the perimeter seals 534, 534 a-534 k shown inFIGS. 15A-15H . Thecab panel 736 e is secured to the side rails 720 a, 720 b by cab panel retainers 779 (FIG. 42D ) and retainer bolt 778; two retainer bolts are illustrated as examples, includinghandle bolt 778 b andhex bolt 778 a (FIG. 421 ). Thecab panel retainers 779 are also engaged with containment brackets orswing containment brackets folding cover assembly 730 with respect to the side rails 720 a, 720 b and thecargo box 5. In some embodiments, the foldingtonneau cover apparatus 730 includeshooks catches tonneau cover apparatus 730 includes hinge supports or hinge support mechanisms 749 (FIG. 42 I) described herein. Thefolding cover assembly 730 preferably includes a pull-down strap assembly 729 (FIG. 42H ) including astrap retainer 729 b and a pull-downstrap 729 a (FIG. 48 ). - A side view of portions of the folding
tonneau cover apparatus 710 is illustrated inFIG. 42C , as viewed fromline 42C-42C ofFIG. 42A , and give further understanding of the relative positioning of the elements. Further detailed views of the foldingtonneau cover apparatus 710 are illustrated inFIGS. 42D-42G .FIG. 42D shows a portion of the foldingtonneau cover apparatus 710 encircled byline 42D-42D onFIG. 42C , illustrating thecab panel 736 e, the rear portion of therear panel 736 a, thesupport bow 750 b mostly obscured bybow end cap 765, thesupport bow 750 h, hinge 744 d, hook 762 e, catch 764 e (FIG. 42F ),swing containment bracket 725 c which keeps latchcab panel retainer 779 in position on theside rail 720 a and helps to maintain thefolding cover assembly 730 at the desired location to cover thecargo box 5. Thecab panel retainer 779 is secured to thesupport bow 750 h byhandle bolt 778 b. - A bottom perspective view of the folding
tonneau cover apparatus 710 is illustrated inFIG. 42E , with a detail view of the portion of the foldingtonneau cover apparatus 710 encircled byline 42F onFIG. 42E being illustrated inFIG. 42F . Thehinge 744 d,swing containment bracket 725 d,cab panel retainer 779, handlebolt 778 b, passengerside support beam 773 b, andbeam end cap 773 c are also shown. - A portion of the driver's side of the hinged
tonneau cover apparatus 710 is illustrated in a partial section view as seen from theline 42G-42G ofFIG. 42A inFIG. 42G , which shows theside support beam 773 b secured to handle 759 by adhesive 770 b. Thesupport bow 750 b is in place on theside rail lip 724 ofside rail 720 a, and perimeter seal 734 seals against theside rail 720 a and theside wall cap 6 e on thedrivers side sidewall 6 a. Theside rail 720 a is secured to thesidewall 6 a by aclamp 714, which preferably includes the anouter member 716 a, aninner member 716 b, aclamp engagement portion 716 c, and afastener assembly 716 d; the fastener assembly can, for example, include abolt 716 e, awasher 716 f and anut 716 g as illustrated. Preferably,inner member 716 b has aclamp engagement portion 716 c which, together with siderail engagement portion 722 a ofside rail 720 a, aids in securing theclamps 714 in place on theside rail 720 a. Preferably, theclamps 714 are arranged and tightened to secure theside rail 720 a to thesidewall 6 a, with asidewall gasket 722 c arranged between theside rail 720 a and thesidewall 6 a as illustrated. Thecab panel retainer 779 and handle bolt are also shown. - An alternate folding
tonneau cover apparatus 710 is shown inFIG. 42H . In this embodiment, thefolding cover assembly 730 includes retainer bolts 778 which arehex bolts 778 a. This embodiment also includes hinge supports or hinge support mechanisms 749 (FIG. 42 I) described herein. Thefolding cover assembly 730 preferably also includes a pull-downstrap assembly 729 including astrap retainer 729 b and a pull-downstrap 729 a (FIG. 48 ). Further details are illustrated inFIG. 42I , which illustrates the front passenger portion of the foldingtonneau cover apparatus 710 ofFIG. 42H , similar to the view ofFIG. 42F . Ahinge support mechanism 749 is shown, as will be more fully described in reference toFIGS. 45-47 . Preferably, thefolding cover assembly 730 includes a pair ofhinge support mechanisms 749 located apart from each other such as illustrated onFIG. 42H . - The hinged or folding cover assembly 740 of
FIG. 42H is further illustrated in a rear perspective view in Fig., with the foldingtonneau cover apparatus 730 attached to apickup truck 2 which is shown partially and in phantom. A partial section view as seen from theline 43B-43B ofFIG. 43A is shown inFIG. 43B , which shows the engaging portion of one of the latches on the rear support bow or support member of the rear panel engaged with the lip of the side rail, and the side rail clamped to the sidewall of the pickup truck with a portion of the truck sidewall and sidewall cap shown in phantom. - As seen in
FIG. 43B , thelatch 752 a includeslatch slide 753 having an engagingportion 753 b which extends forward to engage thelip 724 of theside rail 720 a, so as to secure the panel 730 a to theside rail 720 a. Thelatch slide 753 preferably includes a stiff polymer, composite, or metal, although other materials and combinations can be used. Preferably, thelatch slide 753 includes fiberglass-reinforced nylon. Thelatch slide 753 is biased by a biasing member orspring 756 towards theside rail 720 a so that the engagingportion 753 b engages theside rail 720 a to form a secured configuration in which therear panel 736 a is restricted from being lifted up from thecargo box 5; in this example, thespring 756 is a compression spring, but an extension spring, or an elastic element, or other known elements could alternatively be used to bias thelatch slide 753 towards theside rail 720 a so that the engagingportion 753 b engages theside rail 720 a so that thelatch 752 a is in the secured configuration. In this embodiment, thespring 756 is held between thelatch slide 753 and aspring retainer assembly 757. Thespring retainer assembly 757 is secured in the desired location in thesupport bow 750 a. The side rails 720 a and 720 b preferably include extruded metal, and have a siderail engagement portion 722 a (FIG. 44B ), arranged to approximate a portion of thesidewall pickup truck 2. Theclamp 714 is shown in detail inFIG. 43B . Theclamps 714 preferably include aluminum, although other metals or alloys or polymers or other composite materials can be used.Clamps 714 preferably have anouter member 716 a and aninner member 716 b which are tightened towards each other and held as an assembly on thesidewall 6 a by afastener assembly 716 d which preferably includes abolt 716 e, awasher 716 f, and anut 716 g. Preferably,inner member 716 b has aclamp engagement portion 716 c which, together with siderail engagement portion 722 a ofside rail 720 a, aids in securing theclamps 714 in place on theside rail 720 a. Preferably, theclamps 714 are arranged and tightened to secure theside rail 720 a to thesidewall 6 a, with asidewall gasket 722 c arranged between theside rail 720 a and thesidewall 6 a as illustrated. Abow end cap 765 is located at the end of thesupport bow 750 a. A release cord 754 and acord guide 755 a are shown. The driver's side portion of thesupport bow 750 a is shown inFIG. 43B ; the other end of thesupport bow 750 a (toward the passenger side) has a mirror-image configuration, withlatch 752 b engagingside rail 720 b, andside rail 720 b being attached tosidewall 6 b in a similar manner. - As illustrated in
FIGS. 44A and 44B , when it is desired to release the latches 752 at the rear end of therear panel 736 a, therelease cord 754 a can be pulled, which will retract each of the latches 752 against the force of the respective biasing member orspring 756. Typically, therelease cord 754 a will be pulled by anoperator 8 who has walked to the rear of thecargo box 5 and has opened thetailgate 6 d and reaches in to access and pull therelease cord 754 a. When therelease cord 754 a is pulled, the engagingportion 753 b of thelatch 752 a is retracted away from thelip 724 of theside rail 720 a as shown inFIG. 44B , releasing thelatch 752 a from theside rail 720 a and allowing the rear portion of therear panel 736 a to be lifted up from theside rail 720 a. The cord guides 755 a adjacent to the latches 752 help to maintain alignment of the ends of therelease cord 754 a so that the latches 752 are retracted in alignment with thesupport bow 750 a, to avoid excessive friction, wear and potential binding. The driver's side portion of thesupport bow 750 a is shown inFIG. 44B ; the other end of thesupport bow 750 a (toward the passenger side) has a mirror-image configuration, and when therelease cord 754 a is pulled, the latches 752 at both ends of thesupport bow 750 a are retracted, so that the rear end of therear panel 736 a can be lifted up from bothside rails FIG. 44A , therelease cord 754 a is depicted as being pulled in two location; typically theoperator 8 would pull therelease cord 754 a in only one location, causing both latches to release. -
FIG. 45 illustrates a portion of the hingedcover assembly 730 similar to the portion shown inFIG. 42I , except that the cover assembly is flipped upside down and the drivers side of thefolding cover assembly 730 is shown (which is a mirror image of the passenger side of the folding cover assembly 730) and some parts have been removed to reveal underlying structures including thehinge support mechanism 749, and therear panel 736 a has been lifted up and is shown in a pivoted orientation with respect to thecab panel 736 e.FIGS. 45-47 further illustrate thehinge support mechanism 749. As shown and described herein (seeFIG. 42H ), there are preferably twohinge support mechanisms 749 that help to support and stabilize thefolding cover assembly 730, and therear panel 736 a, and thehinge 744 d as therear panel 736 a is lifted up and thehinge 744 d is bent, when therear panel 736 a pivots with respect to thecab panel 736 e. When it is desired to access thecargo box 5, and therelease cord 754 a is pulled, retracting thelatches rear panel 736 a can be lifted up and rotated forward around a pivot arc Dl. Therear panel 736 a pivots with respect to thecab panel 736 e and generally rotates around ahinge pivot axis 749 h. - The structure of the
hinge 744 d, support bows 750 b, 750 h, and hingesupport mechanisms 749 are generally symmetric with respect to thehinge pivot axis 749 h. Thesupport bow 750 b preferably includes a hinge support flange 786 extending to support thehinge body 745 a and is located adjacent the front edge 741 b of therear panel 736 a in a configuration that is a mirror image of the configuration ofsupport bow 750 h located adjacent the rear edge 741 c of thecab panel 736 e as shown (see alsoFIGS. 35A-35C ). Preferably, eachhinge support mechanism 749 includes ahinge bracket 749 a and ahinge bracket 749 b, and abracket guide pin 749 c which is retained inbracket slots 749 d in each of thehinge brackets hinge bracket bracket block 749 e which protrudes from therespective hinge bracket hinge bracket respective support bow bracket block nut 749 f and abracket block bolt 749 g. Preferably, thebracket slots 749 d are each curved in a circular arc, and when thehinge brackets bracket guide pin 749 c are assembled and thehinge brackets bracket slots 749 d are each curved in a circular arc centered on thehinge pivot axis 749 h, so that when therear panel 736 a is lifted up and theflexible hinge 744 d bends and therear panel 736 a rotates around thehinge pivot axis 749 h, thehinge brackets rear panel 736 a with respect to thecab panel 736 e and support therear panel 736 a so that stress on thehinge 744 d is reduced. - Preferably, there are two
hinge support mechanisms 749 located apart from each other, a firsthinge support mechanism 749 located closer to theside support beam 773 a, and a secondhinge support mechanism 749 located closer to theside support beam 773 b, as illustrated herein. When arranged in this manner and secured as shown, thehinge support mechanisms 749 help to support the front portion of therear panel 736 a when the rear portion of therear panel 736 a is lifted up off the side rails 720 a, 720 b, and help to maintain alignment of therear panel 736 a with respect to thecab panel 636 e, minimizing any relative displacement or skewing, and reducing stress on thehinge 744 d. Thehinge pivot axis 749 h is generally parallel to the hinge longitudinal axis 745 b (see hingelongitudinal axis 545 b onFIG. 17C ) and may be within or proximate to the hinge body 745 c. A perspective view of portions of thehinge support mechanism 749 is shown inFIG. 47 to better show the detailed structure. - As illustrated on
FIG. 45 , thehinge 744 d preferably includes adhesive such as double-sidedadhesive tape 771 c to seal the ends of thehinge body 745 a against theperimeter seal 734 to prevent precipitation or debris entry into thecargo box 5 past thehinge 744 d. Preferably, a short piece of double-sidedadhesive tape 771 c such as about ¼ inch by ⅝ inch is adhered at each end; suitable material includes an adhesive foam tape such as Tesa 7078 acrylic foam tape. Other hinges disclosed herein, including hinges 444, 544, 644, can incorporate such double-sided adhesive tape to similarly provide a weather seal at each end of the respective hinge. - When the
rear panel 736 a is lifted up as illustrated in the rear perspective view of the foldingtonneau cover apparatus 710 shown inFIG. 48 , anoperator 8 can access thecargo box 5, while the gas struts 774 support the weight of thefolding cover assembly 730 as necessary to support therear panel 736 a in the raised position. When it is desired to lower therear panel 736 a to cover thetop opening 6 f and close the folding cover assembly on thecargo box 5, theoperator 8 can grasp the pull-downstrap 729 a, which is secured to thesupport bow 750 a by astrap retainer 729 b. When therear panel 736 a is lowered completely onto the side rails 720 a, 720 b, thelatches side rail lip 724 of each of the side rails 720 a, 720 b and secure thefolding cover assembly 730 to the side rails 720 a, 720 b. - It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
Claims (46)
1. A tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position; the pickup truck further including a cab positioned forward of the cargo box; the tonneau cover apparatus comprising:
a support frame assembly for attachment to the cargo box; and
a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels has an upper surface and a lower surface; and wherein the plurality of rigid panels includes first and second rigid panels foldably secured to one another such that the cover assembly can be folded up when the cover assembly is secured to the support frame such that respective upper surfaces of at least two of the plurality of rigid panels reside in an upright folded orientation in which the upper surfaces of the first and second rigid panels reside in a generally parallel orientation to one another; and
wherein the tonneau cover apparatus further includes means for securing the respective upper surfaces of the first and second rigid panels in the upright folded orientation.
2. The tonneau cover apparatus of claim 1 , wherein said means for securing includes a cab bracket assembly in combination with a cab brace; wherein the cab brace is secured to the cover assembly and the cab bracket is secured to the cab, and wherein the cab brace is engageable with the cab bracket when the cab bracket is secured to the cab such that the cover assembly is secured to the cab such that at least two of the plurality of rigid panels reside in an upright folded orientation.
3. The tonneau cover apparatus of claim 2 , further including a cab panel and a storage retainer secured to the cab panel, the storage retainer including a retainer nest.
4. The tonneau cover apparatus of claim 2 , wherein the cab brace and the cab bracket are attracted to one another by magnetic attraction.
5. The tonneau cover apparatus of claim 2 , wherein the cab bracket includes a magnet and the cab brace includes a material which can be attracted to the magnet.
6. The tonneau cover apparatus of claim 1 , further including a cab panel, wherein said means for securing is selected from the group consisting of a storage strap secured to a support bow and engageable to a storage retainer secured to the cab panel; a panel bracket attached to a top surface of the cab panel and engageable with a storage strap; a cab strap secured to a support bow and engageable with a cab bracket secured to the cab; a side strap secured to a sidebar and securable to the cab; a cab panel strap attached to a support bow and securable to the cab panel; a securing magnet attached to a support bow and engageable with a cab magnet that is secured to the cab; a securing bracket located on at least one of the driver's side and the passenger side and engageable with the folding cover assembly when the folding cover assembly is in an upright folded orientation; and a cab magnet secured to the cab and engageable with a cab brace.
7. The tonneau cover apparatus of claim 1 ; wherein means for securing the respective upper surfaces of the first and second rigid panels in the upright folded orientation includes an elongated rigid member that has first and second ends and the elongated rigid member is bent in such a way that first and second upper surfaces of the respective first and second ends of the elongated rigid member are oriented at an angle to one another of from about 1 degree to about 16 degrees.
8. The tonneau cover apparatus of claim 1 ; wherein the first and second rigid panels are foldably secured to one another by a flexible hinge; and wherein the flexible hinge is secured to the lower surface of each of the first and second rigid panels.
9. The tonneau cover apparatus of claim 1 ; wherein the support frame assembly includes first and second siderails, each of which is attachable to one of the respective opposing sidewalls; wherein at least one of the plurality of rigid panels is secured to both of the respective siderails when the respective siderails are secured to the respective sidewalls and the cover assembly is secured to the support frame.
10. The tonneau cover apparatus of claim 1 , wherein the support frame assembly includes two side rails and at least one catch engaged with one of the two side rails, and wherein the cover assembly further includes at least one hook secured to the second rigid panel, wherein the at least one hook is engaged with the at least one catch to limit movement of the second rigid panel when the second rigid panel is secured to the two side rails and the two siderails are secured to the cargo box; and wherein, when the second rigid panel pivots with respect to the first rigid panel and disengages from the respective side rails, the at least one hook will disengage from the at least one catch.
11. The tonneau cover apparatus of claim 10 , wherein the support frame includes a plurality of catches, and the cover assembly includes a plurality of hooks, and wherein each of the plurality of hooks is engageable with one of the plurality of catches when the second rigid panel is engaged with each of the respective side rails.
12. The tonneau cover apparatus of claim 11 wherein the plurality of rigid panels includes a third rigid panel, and wherein the plurality of hooks includes a hook that is secured to the third rigid panel.
13. The tonneau cover apparatus of claim 10 , wherein the cover assembly includes at least one locking member secured to one of the plurality of rigid panels; wherein the locking member is engageable with one of the respective side rails, when the respective side rail is secured to the cargo box, so as to engage the cover assembly with the support frame assembly and the cargo box; wherein the locking member is prevented from disengaging from the respective side rail when the locking member is in a first position and the respective side rail is secured to the cargo box; wherein the locking member can be moved from the first position to a second position; wherein the locking member can disengage from the respective side rail when the respective side rail, when the locking member is in the second position.
14. The tonneau cover apparatus of claim 1 , wherein the cover assembly includes at least one locking member secured to one of the plurality of rigid panels; wherein the locking member is engageable with one of the respective side rails, when the respective side rail is secured to the cargo box, so as to engage the cover assembly with the support frame assembly and the cargo box; wherein the locking member is prevented from disengaging from the respective side rail when the locking member is in a first position and the respective side rail is secured to the cargo box; wherein the locking member can be moved from the first position to a second position; wherein the locking member can disengage from the respective side rail when the respective side rail is secured to the cargo box and the locking member is in the second position.
15. The tonneau cover apparatus of claim 1 , wherein the cover assembly further includes a perimeter seal secured to the an underside of each of the respective rigid panels; wherein the perimeter seal includes a water resistant gasket that forms a border around an underside of the cover assembly so that, when the cover assembly is secured to the side rails of the support frame and the side rails are secured to the cargo box and the tailgate is in the closed position, and the cover assembly is positioned to cover the cargo box, the perimeter seal creates a water resistant barrier between the cover assembly and the top of the perimeter of the cargo box.
16. The tonneau cover apparatus of claim 1 , wherein the upper surface of each of the rigid panels is curved downwardly so as to be at least partially downwardly concave along a width of the respective rigid panels when the respective rigid panel is secured to the side rails.
17. The tonneau cover apparatus of claim 16 , wherein the upper surface of each of the rigid panels is sufficiently curved downward for water to run off of the upper surface of each of the rigid panels under the force of gravity when the cover assembly is engaged with the support frame assembly and positioned to cover the cargo box.
18. A method of removably securing a tonneau cover apparatus to a perimeter of a cargo box of a pickup truck, the perimeter of a cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position; the pickup truck further including a cab positioned forward of the cargo box; said method comprising the steps of:
providing a tonneau cover apparatus including: 1) a support frame assembly for attachment to the cargo box; 2) a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels has an upper surface and a lower surface; and wherein the plurality of rigid panels includes first and second rigid panels foldably secured to one another such that the cover assembly can be folded up, when the cover assembly is secured to the support frame and the support frame is secured to the cargo box, such that respective upper surfaces of the first and second rigid panels reside in an upright folded orientation in which the upper surfaces of the first and second rigid panels reside in a generally parallel orientation to one another; and 3) means for securing the respective first and second rigid panels in the upright folded orientation;
securing the support frame assembly to the cargo box;
securing the cover assembly to the support frame assembly;
positioning the first and second rigid panels in an upright folded orientation in which the upper surfaces of the first and second rigid panels reside in a generally parallel orientation to one another; and
engaging said securing means with the cover assembly so that the first and second rigid panels reside in the upright folded orientation when so secured.
19. The method of claim 18 , wherein said means for securing includes a cab bracket assembly in combination with a cab brace; wherein the cab brace is secured to the cover assembly and the cab bracket is secured to the cab, and wherein the cab brace is engageable with the cab bracket when the cab bracket is secured to the cab such that the cover assembly is secured to the cab such that at least two of the plurality of rigid panels reside in an upright folded orientation.
20. The method of claim 19 , further including a cab panel and a storage retainer secured to the cab panel, the storage retainer including a retainer nest.
21. The method of claim 19 , wherein the cab brace and the cab bracket are attracted to one another by magnetic attraction.
22. The method of claim 19 , wherein the cab bracket includes a magnet and the cab brace includes a material which can be attracted to the magnet.
23. The method of claim 18 , further including a cab panel, wherein said means for securing is selected from the group consisting of a storage strap secured to a support bow and engageable to a storage retainer secured to the cab panel; a panel bracket attached to a top surface of the cab panel and engageable with a storage strap; a cab strap secured to a support bow and engageable with a cab bracket secured to the cab; a side strap secured to a sidebar and securable to the cab; a cab panel strap attached to a support bow and securable to the cab panel; a securing magnet attached to a support bow and engageable with a cab magnet that is secured to the cab; a securing bracket located on at least one of the driver's side and the passenger side and engageable with the folding cover assembly when the folding cover assembly is in an upright folded orientation; and a cab magnet secured to the cab and engageable with a cab brace.
24. The method of claim 18 ; wherein said means for securing includes an elongated rigid member that has first and second ends and the elongated rigid member is bent in such a way that first and second upper surfaces of the respective first and second ends of the elongated rigid member are oriented at an angle to one another of from about 1 degree to about 16 degrees.
25. The method of claim 18 ; wherein the first and second rigid panels are foldably secured to one another by a flexible hinge; and wherein the flexible hinge is secured to the lower surfaces of each of the first and second rigid panels.
26. The method of claim 18 ; wherein the support frame includes first and second siderails, each of which is attachable to one of the respective opposing sidewalls; wherein one of the plurality of rigid panels is secured to both of the respective siderails when the respective siderails are secured to the respective sidewalls.
27. A tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position, the tonneau cover apparatus comprising:
a support frame assembly for attachment to the cargo box; and
a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly having a plurality of rigid panels including first and second rigid panels that are pivotally interconnected with one another by a flexible hinge; wherein each of the respective rigid panels has an upper surface and a lower surface; and wherein the first rigid panel can be secured to the support frame assembly when the support frame assembly is secured to the cargo box;
wherein the cover assembly further includes a hinge support mechanism that helps to maintain alignment of the second panel with respect to the first rigid panel as the second panel pivots about a hinge pivot axis so as to constrain the rotation of the second rigid panel, when the second rigid panel pivots with respect to the first rigid panel, in a manner that reduces stress on the flexible hinge.
28. The tonneau cover apparatus of claim 27 , wherein the first and second rigid panels interconnected by the flexible hinge are adjacent to one another, and wherein the hinge support mechanism includes a pair of opposing hinge brackets, each of which is secured to an opposite opposing adjacent rigid panel in a manner which enables the respective opposing hinge brackets to slide with respect to one another, as the second rigid panel pivots with respect to the first rigid panel, while remaining engaged with one another and restricting the rotation of the second rigid panel with respect to the first rigid panel.
29. The tonneau cover apparatus of claim 28 , wherein each the respective opposing hinge brackets have a guide pin and a slot, wherein when the second rigid panel pivots with respect to the adjacent first rigid panel about the hinge pivot axis, the respective guide pins of the respective hinge brackets slide within the respective slots of the respective opposing hinge brackets.
30. The tonneau cover apparatus of claim 27 , wherein the flexible hinge is secured to the respective lower surfaces of each of the respective first and second rigid panels; and wherein the hinge support mechanism includes first and second pairs of hinge brackets, the first and second pairs of hinge brackets are secured to the upper surfaces of the respective first and second rigid panels in locations that are spaced apart on the upper surfaces of the respective first and second rigid panels.
31. The tonneau cover apparatus of claim 27 , wherein the cover assembly further includes a lift support interconnected between the second rigid panel and the support frame assembly.
32. A tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position, the tonneau cover apparatus comprising:
a support frame assembly for attachment to the cargo box, the support frame assembly including two siderails and at least one catch secured to one of the two siderails; and
a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly having a plurality of rigid panels including first and second rigid panels that are pivotally interconnected with one another by a hinge; wherein each of the respective rigid panels has an upper surface and a lower surface; and wherein the first rigid panel can be secured to the support frame assembly when the support frame assembly is secured to the cargo box;
wherein the cover assembly further includes at least one hook secured to the second rigid panel, the at least one hook being engageable with the at least one catch to limit movement of the second rigid panel when the second rigid panel is positioned to cover at least a portion of the cargo box, and wherein, when the second panel is pivoted with respect to the first panel, the pivoting of the second panel disengages the at least one hook from the at least one catch.
33. The tonneau cover apparatus of claim 32 , wherein the at least one catch includes a plurality of catches, and the at least one hook includes a plurality of hooks, and each of the plurality of hooks is engageable with the one of the plurality of catches to limit movement of the respective rigid panel to which the respective hook is secured.
34. The tonneau cover apparatus of claim 33 wherein the plurality of rigid panels includes a third rigid panel, and wherein the at least one hook includes a hook that is secured to the third rigid panel.
35. The tonneau cover apparatus of claim 32 , further including a securing apparatus, wherein the securing apparatus includes at least one locking member secured to one of the plurality of rigid panels; wherein the locking member is engageable with one of the respective side rails when the respective side rail is secured to the cargo box, so as to engage the cover assembly with the support frame assembly and the cargo box; wherein the locking member is prevented from disengaging from the respective side rail when the locking member is in a first position and the respective side rail is secured to the cargo box; wherein the locking member can be moved from the first position to a second position; wherein the locking member can disengage from the respective side rail when the respective side rail is secured to the cargo box and the locking member is in the second position.
36. The tonneau cover apparatus of claim 32 , further including a perimeter seal secured to the an underside of each of the respective rigid panels; wherein the perimeter seal includes a water resistant gasket that forms a border around an underside of the cover assembly so that, when the cover assembly is secured to the side rails of the support frame and the side rails are secured to the pickup truck and the tailgate is in the closed position, and the cover assembly is positioned to cover the cargo box, the perimeter seal creates a water resistant barrier between the cover assembly and the top of the perimeter of the cargo box.
37. The tonneau cover apparatus of claim 36 , wherein the upper surface of each of the rigid panels is curved downwardly so as to be at least partially downwardly concave along a width of the respective rigid panels when the respective rigid panel is secured to the side rails.
38. The tonneau cover apparatus of claim 37 , wherein the upper surface of each of the rigid panels is sufficiently curved for water to run off of the upper surface of each of the rigid panels under the force of gravity when the cover assembly is engaged with the support frame assembly positioned to cover the cargo box.
39. The tonneau cover apparatus of claim 32 , further comprising a hinge support mechanism that helps to maintain alignment of the second panel with respect to the first panel as the second panel pivots about a hinge pivot axis so as to constrain the rotation of the second panel in a manner that reduces stress on the hinge.
40. A tonneau cover apparatus for removable attachment about a top of a perimeter of a cargo box of a pickup truck, the perimeter of the cargo box including a forward end, two opposing sidewalls and a tailgate, the tailgate being positioned rearward of the forward end and having an open position and a closed position; the tonneau cover apparatus comprising:
a support frame assembly for attachment to the cargo box; and
a cover assembly for attachment to the support frame assembly when the support frame assembly is attached to the cargo box; the cover assembly including a plurality of rigid panels that are foldably interconnected with one another in series; wherein each of the respective rigid panels is interconnected to any adjacent rigid panel in the series of rigid panels with a hinge; wherein the support frame assembly includes two siderails and at least one catch engaged with one of the two siderails, wherein the cover assembly further includes at least one hook secured to one of the plurality of rigid panels, wherein the at least one hook will be engaged with the at least one catch to limit movement of the respective rigid panel to which the at least one hook is secured when the rigid panel is engaged with both of the respective siderails and when both of the respective siderails are secured to the cargo box, and wherein, when the rigid panel to which the hook is secured is folded over and pivots with respect to an adjacent rigid panel to which the respective rigid panel is interconnected, the at least one hook will disengage from the at least one catch.
41. The tonneau cover apparatus of claim 40 , wherein the support frame includes a plurality of catches, and the cover assembly includes a plurality of hooks, wherein each of the plurality of hooks is engageable with one of the plurality of catches when each of the respective plurality of rigid panels to which any one of the respective plurality of hooks is secured, is secured to one of the two respective side rails when the respective side rails are secured to the cargo box.
42. The tonneau cover apparatus of claim 41 , further including securing apparatus, wherein the securing apparatus includes at least one locking member secured to one of the plurality of rigid panels; wherein the locking member is engageable with one of the respective side rails, when the respective side rail is secured to the cargo box, so as to engage the cover assembly with the support frame assembly when the respective side rails are secured to the cargo box; wherein the locking member is prevented from disengaging from the respective side rail when the locking member is in a first position and the respective side rail is secured to the cargo box; wherein the locking member can be moved from the first position to a second position; wherein the locking member can disengage from the respective side rail when the respective side rail is secured to the cargo box and the locking member is in the second position.
43. The tonneau cover apparatus of claim 40 , further including a securing apparatus, wherein the securing apparatus includes at least one locking member secured to one of the plurality of rigid panels; wherein the locking member is engageable with one of the respective side rails when the respective side rail is secured to the cargo box, so as to engage the cover assembly with the support frame assembly and the cargo box; wherein the locking member is prevented from disengaging from the respective side rail when the locking member is in a first position and the respective side rail is secured to the cargo box; wherein the locking member can be moved from the first position to a second position; wherein the locking member can disengage from the respective side rail when the respective side rail is secured to the cargo box and the locking member is in the second position.
44. The tonneau cover apparatus of claim 40 , further including a perimeter seal secured to an underside of each of the respective rigid panels; wherein the perimeter seal includes a water resistant gasket that forms a border around an underside of the cover assembly so that, when the cover assembly is secured to the side rails of the support frame and the side rails are secured to the pickup truck and the tailgate is in the closed position, and the cover assembly is positioned to cover the cargo box, the perimeter seal creates a water resistant barrier between the cover assembly and the top of the perimeter of the cargo box.
45. The tonneau cover apparatus of claim 40 , wherein the upper surface of each of the rigid panels is curved downwardly so as to be at least partially downwardly concave along a width of the respective rigid panels when the respective rigid panel is secured to the side rails.
46. The tonneau cover apparatus of claim 45 , wherein the upper surface of each of the rigid panels is sufficiently curved for water to run off of the upper surface of each of the rigid panels under the force of gravity when the cover assembly is engaged with the support frame assembly and the side rails are secured to the cargo box.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/068,949 US20230121434A1 (en) | 2016-10-28 | 2022-12-20 | Tonneau Cover Having Secured Flexible Hinge |
Applications Claiming Priority (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201662414591P | 2016-10-28 | 2016-10-28 | |
US15/794,549 US10189340B2 (en) | 2016-10-28 | 2017-10-26 | Folding tonneau cover apparatus |
US16/252,345 US11235652B2 (en) | 2016-10-28 | 2019-01-18 | Folding tonneau cover apparatus |
US201962843357P | 2019-05-03 | 2019-05-03 | |
US201962845086P | 2019-05-08 | 2019-05-08 | |
US16/865,132 US11292324B2 (en) | 2017-10-26 | 2020-05-01 | Folding tonneau cover having secured flexible hinge |
US17/089,611 US11642948B2 (en) | 2016-10-28 | 2020-11-04 | Tonneau cover having secured flexible hinge |
US18/068,949 US20230121434A1 (en) | 2016-10-28 | 2022-12-20 | Tonneau Cover Having Secured Flexible Hinge |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/089,611 Continuation US11642948B2 (en) | 2016-10-28 | 2020-11-04 | Tonneau cover having secured flexible hinge |
Publications (1)
Publication Number | Publication Date |
---|---|
US20230121434A1 true US20230121434A1 (en) | 2023-04-20 |
Family
ID=75492543
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/089,611 Active 2038-06-17 US11642948B2 (en) | 2016-10-28 | 2020-11-04 | Tonneau cover having secured flexible hinge |
US18/068,949 Pending US20230121434A1 (en) | 2016-10-28 | 2022-12-20 | Tonneau Cover Having Secured Flexible Hinge |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/089,611 Active 2038-06-17 US11642948B2 (en) | 2016-10-28 | 2020-11-04 | Tonneau cover having secured flexible hinge |
Country Status (1)
Country | Link |
---|---|
US (2) | US11642948B2 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11642948B2 (en) * | 2016-10-28 | 2023-05-09 | Agri-Cover, Inc. | Tonneau cover having secured flexible hinge |
CN210822004U (en) * | 2019-07-29 | 2020-06-23 | 常州市盛沃国际贸易有限公司 | Compartment cover locking device, compartment and truck |
CN111717007B (en) * | 2020-06-22 | 2023-06-09 | 杭州金日汽车零部件有限公司 | Clip locking piece device |
US10994648B1 (en) * | 2020-12-11 | 2021-05-04 | Tianjin Regis Star Group Co., Ltd | Cover assembly for a bed of a vehicle |
CA3152439A1 (en) * | 2021-06-02 | 2022-12-02 | Martin Keding | Apparatus for locking a truck cover against unauthorized release |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5427428A (en) * | 1993-10-04 | 1995-06-27 | Ericson; John C. | Folding cover for the bed of a pickup truck |
US6352296B1 (en) * | 1998-04-28 | 2002-03-05 | Advance Cover Company | Folding cover for pickup truck bed |
US8690224B2 (en) * | 2006-09-29 | 2014-04-08 | Israel Maimin | Pick-up truck box cover |
US20180093555A1 (en) * | 2015-03-30 | 2018-04-05 | Jennifer Aubrey | Load bearing tonneau cover with integral track, improved latch to vehicle and custom frame attachment |
US11235652B2 (en) * | 2016-10-28 | 2022-02-01 | Agh-Cover, Inc. | Folding tonneau cover apparatus |
US11642948B2 (en) * | 2016-10-28 | 2023-05-09 | Agri-Cover, Inc. | Tonneau cover having secured flexible hinge |
Family Cites Families (137)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1215223A (en) | 1914-10-03 | 1917-02-06 | William Hughes Vanderpoel | Asbestos mat. |
US2906323A (en) | 1956-02-23 | 1959-09-29 | Artcraft Venetian Blind Mfg Co | Combined awning and shutter construction |
US3923334A (en) | 1974-03-22 | 1975-12-02 | Hugh L Key | Vehicle bed cover assembly |
US4036521A (en) | 1974-12-23 | 1977-07-19 | Clenet Alain Jean Marie | Truck cover assembly |
US4272119A (en) | 1976-03-10 | 1981-06-09 | Adams Robert M | Vehicle cover assembly |
US4221423A (en) | 1978-11-01 | 1980-09-09 | Stone Raymond J | Cover for a vehicle box |
US4273377A (en) | 1979-04-09 | 1981-06-16 | Alexander Ronald R | Tonneau cover apparatus for pickup truck vehicles |
FR2521973A1 (en) | 1982-02-24 | 1983-08-26 | Commissariat Energie Atomique | PROCESS FOR PURIFYING URANIUM HEXAFLUORIDE CONTAINING TRACES OF PLUTONIUM FLUORIDE AND / OR NEPTUNIUM FLUORIDE |
US4532973A (en) | 1983-06-15 | 1985-08-06 | Defalco Ralph | Overhead door construction |
US5058652A (en) | 1984-09-14 | 1991-10-22 | Wheatley Donald G | Tonneau cover |
US5251951A (en) | 1984-09-14 | 1993-10-12 | Wheatley Donald G | Tonneau cover and support means |
US4747441A (en) | 1986-06-25 | 1988-05-31 | Apolzer Donald G | Foldable cover assembly |
US4730865A (en) | 1986-12-30 | 1988-03-15 | Tadashi Iwata | Assembly for securing a windshield cover to a vehicle |
US4838602A (en) | 1987-03-20 | 1989-06-13 | Nett James A | Pickup bed tonneau cover mounting |
US4807921A (en) | 1987-07-16 | 1989-02-28 | Champie Iii James M | Sliding cover for truck bed |
US4861092A (en) | 1987-07-28 | 1989-08-29 | Bogard Donald E | Pick-up truck tonneau cover |
US4844531A (en) | 1988-01-04 | 1989-07-04 | Steffens Enterprises, Inc. | Folding cover for pickup box |
US4923240A (en) | 1988-10-11 | 1990-05-08 | Swanson Thomas E | Apparatus for releasably securing a cover to a structure |
US5174353A (en) | 1989-02-15 | 1992-12-29 | Agri-Cover, Inc. | Apparatus for covering an opening defined in a structure |
US5076338A (en) | 1989-02-15 | 1991-12-31 | Agri-Cover, Inc. | Apparatus for covering an opening defined in a structure |
US5026109A (en) | 1989-09-28 | 1991-06-25 | Sundance, Inc. | Segmented cover system |
US5040843A (en) | 1990-02-01 | 1991-08-20 | E. L. "Jack" Shockey | Roll-up pickup bed cover with integral tailgate cover and lock |
US5067766A (en) | 1990-05-23 | 1991-11-26 | Lovaas Olaf K | Telescoping cover for a pickup truck bed |
US5584521A (en) | 1992-01-21 | 1996-12-17 | Cr&I Inc. | Vehicle modular rail system |
US5263761A (en) | 1992-01-21 | 1993-11-23 | Cr&I Inc. | Vehicle modular rail system |
US5385377A (en) | 1992-10-08 | 1995-01-31 | Canvasback Convertible Tops Inc. | Pickup truck bed covers and attachment system therefore |
US5350213A (en) | 1993-03-12 | 1994-09-27 | Bernardo Richard G | Apparatus for positioning, latching and locking a retractable truck bed cover |
US5364154A (en) | 1993-07-09 | 1994-11-15 | Sierra Line Products, Inc. | Liftable rigid truck bed cover |
US5522635A (en) | 1994-01-28 | 1996-06-04 | Downey; Darrin | Tonneau cover and frame for pick-up trucks |
US5553652A (en) | 1994-06-27 | 1996-09-10 | Covercraft Industries | Tonneau cover system |
US5540475A (en) | 1994-07-05 | 1996-07-30 | Custom Form Manufacturing, Inc. | Tonneau cover assembly clamping assembly |
US5487585A (en) | 1994-09-12 | 1996-01-30 | Wheatley; Donald G. | Release for flexible tonneau cover |
US6608220B1 (en) | 1994-10-27 | 2003-08-19 | Pharmacia & Upjohn Company | Conversion of bisnoralcohol to bisnoraldehyde |
US5636893A (en) | 1995-04-17 | 1997-06-10 | Wheatley; Donald E. | Folding hard panel tonneau cover with rail attachment |
US5688017A (en) | 1995-06-07 | 1997-11-18 | Bennett; Bruce A. | Method and apparatus for mounting framed tonneau cover |
US5595417A (en) | 1995-07-26 | 1997-01-21 | Thoman; David C. | Tonneau cover for a pick-up truck |
US5653491A (en) | 1995-09-15 | 1997-08-05 | Steffens Enterprises, Inc. | Folding cargo bay cover for pickup trucks |
US5765902A (en) | 1995-11-17 | 1998-06-16 | Grrreat Creations, Inc. | Clamping device |
US5860691A (en) | 1996-03-22 | 1999-01-19 | Lund Industries, Incorporated | Apparatus for covering a vehicle cargo area |
US5655808A (en) | 1996-05-29 | 1997-08-12 | Wheatley; Donald G. | Clamp for attaching a rail to a pick-up box |
US5788315A (en) | 1996-06-03 | 1998-08-04 | Design Automotive Group, Inc. | Tonneau cover apparatus |
US5775765A (en) | 1996-08-26 | 1998-07-07 | Kintz; Robert A. | Truck bed tarp and storing system |
US5758922A (en) | 1996-09-04 | 1998-06-02 | Wheatley; Donald G. | Tonneau cover with magnetic attachment |
US6024401A (en) | 1996-12-09 | 2000-02-15 | Wheatley; Donald G. | Tonneau cover with ball and socket rear rail latch |
US6030021A (en) | 1997-01-03 | 2000-02-29 | Ronai; Christian | Bed cover assembly for a vehicle bed |
US5921603A (en) | 1997-02-27 | 1999-07-13 | Karrer; Robert B. | Attachment system for pickup trucks |
US5931521A (en) | 1997-05-29 | 1999-08-03 | Kooiker; John | Folding cover for pickup truck bed |
US6053558A (en) | 1997-10-01 | 2000-04-25 | Penda Corporation | Cover assembly for the cargo area of a vehicle |
US6024402A (en) | 1997-11-21 | 2000-02-15 | Wheatley; Donald G. | Accessory system for a vehicle cargo box |
US6053556A (en) | 1998-01-13 | 2000-04-25 | Webb; Robert O. | Retractable cover apparatus for truck beds |
EP1062120A4 (en) | 1998-01-16 | 2004-06-09 | Bestop Inc | Tonneau cover system |
US6257647B1 (en) | 1998-01-16 | 2001-07-10 | Bestop, Inc. | Tonneau cover system |
US5906407A (en) | 1998-07-27 | 1999-05-25 | Schmeichel; Charles Milton | Tonneau cover tension adjuster apparatus |
US6234561B1 (en) | 1998-09-11 | 2001-05-22 | Bestop, Inc. | Combination of a lockable, soft tonneau cover and lockable tailgate |
US6082806A (en) | 1998-10-16 | 2000-07-04 | Bogard; Donald E. | Pick-up truck tonneau cover |
US6427500B1 (en) | 1998-11-09 | 2002-08-06 | The Eastern Company | Latch, lock and hinge system for use with closures such as tonneau covers |
US6207092B1 (en) | 1999-05-28 | 2001-03-27 | K. Jabat, Inc. | Process for making a drag shield for a power mower |
US6257306B1 (en) | 1999-06-29 | 2001-07-10 | Penda Corporation | Snap/snapless cover for the cargo area of a vehicle |
US6183035B1 (en) | 1999-09-02 | 2001-02-06 | The Budd Company | Tonneau cover and attachment assembly |
US6422635B1 (en) | 2000-01-20 | 2002-07-23 | Steffens Enterprises, Inc. | Folding cargo bay cover for pickup truck |
US7066524B2 (en) | 2000-08-14 | 2006-06-27 | Agri-Cover, Inc. | Tonneau cover with turn knob for rear bar locks |
CA2316587C (en) | 2000-08-14 | 2009-12-01 | Charles M. Schmeichel | Tonneau cover having rear bar lock |
US6439640B1 (en) | 2001-02-12 | 2002-08-27 | Donald G. Wheatley | Pivoting rail having tonneau cover system |
US6499791B2 (en) | 2001-06-01 | 2002-12-31 | Donald G. Wheatley | Hinged j-strip for a tonneau cover |
US6568740B1 (en) | 2001-10-31 | 2003-05-27 | Shur Company | Cover system for truck box with fastening means |
US7445264B2 (en) | 2001-10-31 | 2008-11-04 | Truxedo, Inc. | Cover system for truck box |
US6575520B1 (en) | 2001-10-31 | 2003-06-10 | Shur Company | Cover system for truck box with tension control |
US6719363B2 (en) | 2002-09-12 | 2004-04-13 | Collins & Aikman Products Co. | Hinge apparatus for vehicle floor systems |
US6948761B2 (en) | 2002-11-01 | 2005-09-27 | The Colonel's International, Inc. | Tonneau cover apparatus |
US7258387B2 (en) | 2002-11-04 | 2007-08-21 | Ross Weldy | Clamp for a tonneau cover |
US7334830B2 (en) | 2002-11-04 | 2008-02-26 | Ross Weldy | Tonneau cover |
US6811203B2 (en) | 2002-12-30 | 2004-11-02 | Donald G. Wheatley | Roll up tonneau cover system |
US6752449B1 (en) | 2002-12-30 | 2004-06-22 | Donald G. Wheatley | Roll up tonneau cover system |
US6883855B2 (en) | 2003-04-01 | 2005-04-26 | Diamondback Automotive Accessories, Inc. | Hinged tonneau cover for transporting a significant top load |
US6719353B1 (en) | 2003-05-29 | 2004-04-13 | Mark Isler | Roll up tonneau cover |
US7066523B2 (en) | 2003-06-11 | 2006-06-27 | Asc Incorporated | Tonneau cover for automotive vehicle |
US7427095B2 (en) | 2004-04-16 | 2008-09-23 | Wheatley Donald G | Covering structure having automatic coupling system |
US7484790B2 (en) | 2004-04-16 | 2009-02-03 | Wheatley Donald G | Covering structure having automatic coupling system |
US6899372B1 (en) | 2004-07-14 | 2005-05-31 | William Bruce Keller | Pickup bed cover |
US20080129077A1 (en) | 2004-09-13 | 2008-06-05 | Ross Weldy | Tonneau cover |
CN100363200C (en) | 2005-02-28 | 2008-01-23 | 史航 | Enclosed pickup automobile tank and tank cover assembly |
US7188888B2 (en) | 2005-05-31 | 2007-03-13 | Wheatley Donald G | Tonneau system latch |
US7685676B2 (en) | 2006-02-24 | 2010-03-30 | Mc Clellan W Thomas | Living hinge |
US7828361B1 (en) | 2006-09-13 | 2010-11-09 | Truxedo, Inc. | Tonneau cover |
US7628442B1 (en) | 2006-10-25 | 2009-12-08 | Truxedo, Inc. | Quick release clamp for tonneau cover |
US7484788B2 (en) | 2006-10-26 | 2009-02-03 | Extang Corporation | Solid fold tonneau system |
US7815239B1 (en) | 2007-10-26 | 2010-10-19 | Agri-Cover, Inc. | Tonneau cover assemblies |
US7735881B2 (en) | 2007-12-07 | 2010-06-15 | Steffens Enterprises, Inc. | Folding cargo bay cover for pickup truck |
CA2661059A1 (en) | 2008-03-31 | 2009-09-30 | Truxedo, Inc. | Tonneau cover cargo containment track rail system |
US20100019529A1 (en) | 2008-07-24 | 2010-01-28 | Travis Alston | Truck Bed Cover and Method |
US7823957B2 (en) | 2008-08-14 | 2010-11-02 | Rugged Liner | Clamp mechanism for a cover assembly |
FR2936551B1 (en) | 2008-09-26 | 2014-01-17 | Centre Nat Etd Spatiales | DEVICE COMPRISING AT LEAST ONE INTEGRATED HINGE IN COMPOSITE MATERIAL WITH UNINTERRUPTED BOND REINFORCEMENT. |
US8348328B2 (en) | 2008-10-31 | 2013-01-08 | Rugged Liner | Sealing hinge for a rigid tonneau cover |
US7954876B2 (en) | 2008-12-02 | 2011-06-07 | Rugged Liner | Tensioner and fastening device for a tonneau cover |
US8308218B2 (en) | 2008-12-11 | 2012-11-13 | Truxedo Inc. | Bi-fold popup soft tonneau cover |
US7905536B2 (en) | 2009-04-24 | 2011-03-15 | Cyc Engineering, Inc. | Clamp structure for tonneau cover |
US8262148B2 (en) | 2009-10-30 | 2012-09-11 | Extang Corporation | Tonneau cover system |
US8585120B2 (en) | 2009-10-30 | 2013-11-19 | Extang Corporation | Tonneau cover retention and drain systems |
USD620877S1 (en) | 2009-11-02 | 2010-08-03 | Extang Corporation | Tonneau cover |
US8336946B2 (en) | 2010-01-13 | 2012-12-25 | Honda Motor Co., Ltd. | Tonneau cover assembly for a vehicle |
USD639229S1 (en) | 2010-03-04 | 2011-06-07 | SolarCar B.V. | Solar top |
US8128149B1 (en) | 2010-08-31 | 2012-03-06 | Wolf Mark A | System for securing a truck bed cover |
US8544708B2 (en) | 2010-10-11 | 2013-10-01 | Julian Maimin | Folding pick-up truck tool box |
US8480154B2 (en) | 2011-04-28 | 2013-07-09 | Cyc Engineering, Inc. | Clamp structure for tonneau cover of pick-up truck |
US8632114B2 (en) | 2011-04-28 | 2014-01-21 | Cyc Engineering, Inc. | Composite tonneau cover of pick-up truck |
US8523266B2 (en) | 2011-04-28 | 2013-09-03 | Cyc Engineering, Inc. | Side fastening assembly for flexible tonneau cover system of pick-up truck |
US8511736B2 (en) | 2011-07-12 | 2013-08-20 | Rugged Liner, Inc. | Rigid tonneau cover and clamp mechanism therefor |
US8573678B2 (en) | 2011-08-03 | 2013-11-05 | Cyc Engineering, Inc. | Tension control assembly for flexible tonneau cover system of pick-up truck |
US8857887B1 (en) | 2011-08-31 | 2014-10-14 | Agri-Cover, Inc. | Tonneau cover having magnetic fasteners |
US8714622B2 (en) | 2011-10-27 | 2014-05-06 | Truxedo, Inc. | Spring Retainer for tonneau cover |
US8544934B2 (en) | 2011-10-31 | 2013-10-01 | Israel Maimin | Roll up pick-up truck box cover with lock down slats |
US9527373B2 (en) | 2011-11-04 | 2016-12-27 | Cyc Engineering, Inc. | Corner assembly for tonneau cover system of pick-up truck |
US9254735B2 (en) | 2012-08-10 | 2016-02-09 | Truxedo, Inc. | Tonneau cover latch system |
US8960764B2 (en) | 2012-08-13 | 2015-02-24 | Extang Corporation | Tonneau cover locking spring clamp |
USD687760S1 (en) | 2012-10-05 | 2013-08-13 | Gene Gros | Tonneau cover |
USD687761S1 (en) | 2012-10-05 | 2013-08-13 | Gene Gros | Tonneau cover |
US8960765B2 (en) | 2012-11-30 | 2015-02-24 | Extang Corporation | Flexible folding cover |
US9211834B2 (en) | 2013-08-29 | 2015-12-15 | Extang Corporation | Tri-fold hard tonneau cover with hinged front opening |
US20150123421A1 (en) | 2013-11-04 | 2015-05-07 | II Robert B. Combs | Vehicle bed cover system and storage assembly |
US9333842B2 (en) | 2013-12-17 | 2016-05-10 | Cyc Engineering, Inc. | Foldable tonneau cover for pick-up truck and hidden-type hinge thereof |
US9039066B1 (en) | 2013-12-17 | 2015-05-26 | Cyc Engineering, Inc. | Foldable tonneau cover for pick-up truck and waterproof flexible strip thereof |
USD727244S1 (en) | 2014-06-16 | 2015-04-21 | Kawasaki Jukogyo Kabushiki Kaisha | Roof for utility vehicles |
USD733033S1 (en) | 2014-08-05 | 2015-06-30 | A.R.E. Accessories, Llc | Truck cap assembly |
US9630479B2 (en) | 2014-10-07 | 2017-04-25 | Extang Corporation | Tonneau cover system and ratchet clamp |
US10144276B2 (en) | 2014-10-07 | 2018-12-04 | Extang Corporation | Tonneau cover system and ratchet clamp |
US9764628B2 (en) | 2014-10-07 | 2017-09-19 | Extang Corporation | Tonneau cover system and side lock clamp |
US9421851B2 (en) | 2015-01-08 | 2016-08-23 | Toyota Motor Engineering & Manufacturing North America, Inc. | Tonneau cover latch apparatus |
USD776601S1 (en) | 2015-05-19 | 2017-01-17 | Truck Accessories Group, Llc | Tonneau cover |
USD766797S1 (en) | 2015-06-11 | 2016-09-20 | M2 Distribution Ltd. | Step for vehicles |
US9694657B2 (en) | 2015-11-23 | 2017-07-04 | Truxedo, Inc. | Tonneau cover system for a cargo box with side rail end plugs with external mounting extensions |
US9738143B2 (en) | 2016-01-27 | 2017-08-22 | Retrax Holdings, Llc | Self-storing folding tonneau cover |
US9597995B1 (en) | 2016-02-26 | 2017-03-21 | Retrax Holdings, Llc | Folding, storing tonneau cover |
US9815357B2 (en) | 2016-04-12 | 2017-11-14 | Laurmark Enterprises, Inc. | Tonneau cover system with cam locking prop-rod |
US9815358B1 (en) | 2016-06-28 | 2017-11-14 | Undercover, Inc. | Foldable tonneau cover with an extruded forward section |
US9895963B1 (en) | 2016-10-11 | 2018-02-20 | Truxedo, Inc. | Tonneau cover system with single piece spanning multiple panels |
US10406897B2 (en) | 2017-06-14 | 2019-09-10 | Truxedo, Inc. | Hard rollup tonneau cover with flexible hold down |
US10406899B2 (en) | 2017-07-06 | 2019-09-10 | Extang Corporation | Tonneau cover system with intermediate automatic latching |
-
2020
- 2020-11-04 US US17/089,611 patent/US11642948B2/en active Active
-
2022
- 2022-12-20 US US18/068,949 patent/US20230121434A1/en active Pending
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5427428A (en) * | 1993-10-04 | 1995-06-27 | Ericson; John C. | Folding cover for the bed of a pickup truck |
US6352296B1 (en) * | 1998-04-28 | 2002-03-05 | Advance Cover Company | Folding cover for pickup truck bed |
US8690224B2 (en) * | 2006-09-29 | 2014-04-08 | Israel Maimin | Pick-up truck box cover |
US20180093555A1 (en) * | 2015-03-30 | 2018-04-05 | Jennifer Aubrey | Load bearing tonneau cover with integral track, improved latch to vehicle and custom frame attachment |
US11235652B2 (en) * | 2016-10-28 | 2022-02-01 | Agh-Cover, Inc. | Folding tonneau cover apparatus |
US11642948B2 (en) * | 2016-10-28 | 2023-05-09 | Agri-Cover, Inc. | Tonneau cover having secured flexible hinge |
Also Published As
Publication number | Publication date |
---|---|
US11642948B2 (en) | 2023-05-09 |
US20210114446A1 (en) | 2021-04-22 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11685242B2 (en) | Folding tonneau cover apparatus | |
US11292324B2 (en) | Folding tonneau cover having secured flexible hinge | |
US11642948B2 (en) | Tonneau cover having secured flexible hinge | |
US20220219516A1 (en) | Folding Tonneau Cover Having Secured Flexible Hinge | |
US11331989B2 (en) | Tonneau cover access panel | |
US9694656B2 (en) | Truck box cover with lock down elements | |
EP3863875B1 (en) | Tonneau cover tie-down assembly | |
US4873800A (en) | Loading dock seal | |
US8256820B2 (en) | Adjustable toolbox | |
US5953868A (en) | Loading dock seal assembly | |
US6862825B1 (en) | Mounting of flexible display panels | |
US7588045B2 (en) | Collapsible structure with door mechanism | |
US7887114B2 (en) | Adjustable toolbox | |
CA3019123C (en) | Weather barriers for vehicle loading docks | |
CA3116670A1 (en) | Tonneau cover having secured flexible hinge | |
US11485206B2 (en) | Fastening system for tonneau covers |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: AGRI-COVER, INC., NORTH DAKOTA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SCHMEICHEL, CHARLES M.;BOHN, BRENDAN T.;BEAM, MARK E.;AND OTHERS;REEL/FRAME:062236/0189 Effective date: 20210331 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |